COOLER UNDER PRESSURE
NISSENS explains the common issues faced by intercoolers as a result of more cars
being fitted with turbocharged engines.
With the demand for smaller, yet more powerful, fuel-efficient and low-
emission engines on the rise, the trend for more passenger cars fitted with
turbocharged engines is growing proportionately as well. Currently, more
than 43% of the EU car parc is fitted with a turbo. This figure is expected to
increase by 30% by 2019.
PROS AND CONS
Since its introduction more than 30 years ago, turbochargers have halved in
size whilst RPM and pressures have doubled. This has led to the increase of
air temperature within the system which then needs to be cooled in order to
gain the desired effect. The vast benefits of turbocharged engines are evident
as they optimise the systems by pushing them to the limit.
However, turbocharged engines do cause some issues. As the difference
between the input and output air temperature of the intercooler is increased
due to the turbo, it puts the intercooler under more pressure and strain. This
can lead to failure if the turbo and intercooler are not installed properly.
WHAT’S THE ISSUE?
LEAKING
INTERCOOLERS
CLOGGED
INTERCOOLERS
Intercoolers are typically
susceptible to external
damage and leakage
caused by road debris.
However, with the
increased popularity
of turbos, two complex
issues are becoming
increasingly prevalent:
Turbo replacements must
be installed according to
guidelines. Otherwise,
turbo residues such as oil,
broken turbo parts and
other impurities can easily
clog the intercooler.
If residues are left in
the system after an
installation, a blockage
can develop. This causes
the pressure within the
system to increase.
When abnormally high
system pressures caused
by blockages exceed
the pressure threshold
of the intercooler, it can
cause the plastic tank to
warp. This leads to the
intercooler leaking.
When the pressure in a turbocharged
system is incorrect, the engine power
SYMPTOMS
OF DEFECTS
Defective or leaking
intercoolers can
manifest a variety of
symptoms. The most
common are:
decreases due to insufficient oxygen
in the fuel/air mixture. This affects the
combustion process which forces the
Noticeable
drop in engine
power
vehicle to increase fuel cons