PRESSURE TO BE COOL
NISSENS explains how the infiltration of turbocharger applications affect the technology of intercoolers .
According to studies , 43 % of vehicles in the current car parc are fitted with turbochargers . This figure is expected to increase by up to 30 % by 2019 . Some studies estimate that 75 % of all European vehicles launched in the coming years will have turbos and intercoolers fitted .
WHAT THE STATISTICS MEAN
The increase in cars and vans with turbos has been evident in the last 10 years and will continue to grow in terms of market opportunities as car manufacturers are required to reduce emissions of petrol and diesel cars , without compromising on performance . In order to maintain high brake horsepower ( BHP ) but with reduced CO2 figures , the automotive sector is seeing more conversions to smaller engines that are fitted with turbochargers .
PUSHING BACK AGAINST PRESSURE
DEMAND FOR REPLACEMENTS
Most intercoolers are front mounted , in most cases attached to the radiator module . This means that they can suffer from external damage and leakage caused by road debris . Whilst these are the main causes , the increased use of turbochargers can lead to clogged and leaking intercoolers as a result of abnormally high system pressure .
When a turbocharger has seized or suffered from an internal failure , experts recommend that the intercooler be replaced as the debris from a failed turbocharger is sent through the intercooler . If the intercooler is not replaced , debris can be recirculated back into the system , causing premature damage and the voiding of warranty . Comparing the cost of intercooler replacements with a turbocharger , it is a sensible and worthwhile replacement if the failure occurs .
Turbos today produce twice the amount of RPM , pressure and temperature while being half the size of their predecessors 30 years ago . This environment increases the pressure of the intercooler due to the drastic difference between the input and output air temperature of the intercooler .
This has created an aftermarket demand for more advanced watercooled intercooler replacements . These intercoolers are becoming more prevalent on EURO 6 applications . The heat exchange occurs between water and air which creates advantages including high efficiency and smaller intercoolers . This efficiency can be boosted using ice or chemicals while providing more flexibility in terms of placement in the charge system pipes .
THE NISSENS WAY
Intercoolers function as a heat exchanger as they reduce the temperature of hot air compressed by the turbocharger before it returns to the engine combustion chamber . This is how they fit into the Nissens engine cooling range .
Nissens has more than 425 part numbers in range covering over 99 % of the top 100 car models in Europe .
With new parts added to range regularly , intercooler highlights include :
• 96222 for Ford Ranger 2.2 TDCi ( 2005-2011 )
• 96486 for Ford Transit DW12 with sensor hole ( 2006 >)
• 961433 for Nissan Juke / NV200 / Pulsar 1.5 DCi ( 2010 >)
Intercoolers function as a heat exchanger , reducing the temperature of the intake air compressed by the turbocharger before it enters the combustion chamber
Catalogued on the F : Drive and MAM Autocat , Nissens intercoolers are available from FPS via same / next-day delivery . For more information , please speak to your local FPS representative .
VITAL NEWS ISSUE 51 INTERCOOLERS 15