Best way to monitor water to air intercooler performance

[Kanaljen]

Puzzling together a water-to-air intercooler system for my vortech kit.

My question for you is around the monitoring of its performance. I want to know that the water pump is running.. that the air gets cooled, etc.

I was thinking about a dual gauge measuring two air temps. One would show the air temp right after the SC but before the intercooler and one would show the the air temp right after the intercooler before the TB.

That way I should see the temp of the compressed air (which should be pretty high, especially on hot days) and the temp of the compressed and cooled air; side by side! If one states 150F and one 70F, my kit would do a pretty good job... If the temp is the same, the water pump might not be running.. etc..

Your thoughts and experiences please!! Best way to do it? Is there a good gauge (digital maybe) that can show two air temps?

[MATT0404]

You'd most likely have to buy two AIT gauges and figure out a functional mounting solution. Although, from my STi and Evo days, I remember that Lindsey Racing used to sell a product that could monitor up to three temp readings and display them all on the same gauge. A lot of people would run a reading before the IC, after the IC and the last reading would be the difference between the two. They don't have that listed on their site but if you sent them a message I'm sure they could help you out.

Other options are:

http://www.frozenboost.com/product_info.php?products_id=800

http://www.plxdevices.com/products/dm5/ait/

The first one looks pretty cheap IMHO. The second one is from PLX who make some of the best gauges on the market. The only downfall for the PLX is that you'd have to purchase the SM-AIT sensor module in conjunction with the two gauges.

I'm sure I'm leaving some stuff out, but there is a ton of info out there on this subject. You could check out some of the forced induction car forums like, nasioc.com, evolutionm.net, etc.. Good luck, I'm sure you'll find something that works.

[TxZHP04]

A couple of thoughts, not really answers though.

First, you should be able to hear the pump running. Maybe not while driving but enough to know it's still alive from time to time. For example, the pump on my ESS kit runs for a few seconds after turning off the car. It provides a nice little reminder that the pump is functional.

Second, if coolant stops circulating, you should notice the drop in power while driving. If you have a good tune, you should lose power safely without having to worry about detonation. This is what happened with my TS before I figured out how to adequately bleed the coolant system.

Third, make sure you develop a good way to bleed the system. :)

EDIT: The Eurosport E36 TS kit had what I thought was a nice touch. IIRC, Josh somehow tied a fluid level sensor in the reservoir for the intercooler to the factory low coolant light on the dash. This wouldn't warn you if the fluid weren't circulating (ie, air in the lines or the pump died) but it would let you know if you had a leak. Don't know if this could easily be done on the e46 though.

EDIT2: I would be careful inserting anything into the intake stream. First, it would be a flow restriction. Second, it would create additional places for future intake leaks.

[Kanaljen]

Great info, thanks! Yeah the plx gauges can do tons of stuff but get costly quickly.. They even have a dual gauge that you can customize!

Thanks again!

You'd most likely have to buy two AIT gauges and figure out a functional mounting solution. Although, from my STi and Evo days, I remember that Lindsey Racing used to sell a product that could monitor up to three temp readings and display them all on the same gauge. A lot of people would run a reading before the IC, after the IC and the last reading would be the difference between the two. They don't have that listed on their site but if you sent them a message I'm sure they could help you out.

Other options are:

http://www.frozenboost.com/product_info.php?products_id=800

http://www.plxdevices.com/products/dm5/ait/

The first one looks pretty cheap IMHO. The second one is from PLX who make some of the best gauges on the market. The only downfall for the PLX is that you'd have to purchase the SM-AIT sensor module in conjunction with the two gauges.

I'm sure I'm leaving some stuff out, but there is a ton of info out there on this subject. You could check out some of the forced induction car forums like, nasioc.com, evolutionm.net, etc.. Good luck, I'm sure you'll find something that works.

[Kanaljen]

More good info! Thanks for taking the time!

You gavce me some good ideas around the water pump and also how to tie in the a in-dash sensor for the water level in the system! Pretty much just parallel it to the wind shield washer sensor....

I found two nice gauges:
- SP Engineering intercooler temperature meter (small, would fit anywhere, intake, outtake and the difference)
- Dual Temperature Gauge DG 210 (bigger, harder to fit, nice ember light matching the interior, like to see the two temps at the same time without having to switch. AND, I think this one has external switching capabitly which can come in handy for the fan and water pump maybe...

Thanks! Great stuff!

A couple of thoughts, not really answers though.

First, you should be able to hear the pump running. Maybe not while driving but enough to know it's still alive from time to time. For example, the pump on my ESS kit runs for a few seconds after turning off the car. It provides a nice little reminder that the pump is functional.

Second, if coolant stops circulating, you should notice the drop in power while driving. If you have a good tune, you should lose power safely without having to worry about detonation. This is what happened with my TS before I figured out how to adequately bleed the coolant system.

Third, make sure you develop a good way to bleed the system. :)

EDIT: The Eurosport E36 TS kit had what I thought was a nice touch. IIRC, Josh somehow tied a fluid level sensor in the reservoir for the intercooler to the factory low coolant light on the dash. This wouldn't warn you if the fluid weren't circulating (ie, air in the lines or the pump died) but it would let you know if you had a leak. Don't know if this could easily be done on the e46 though.

EDIT2: I would be careful inserting anything into the intake stream. First, it would be a flow restriction. Second, it would create additional places for future intake leaks.

[MATT0404]

That SP Engineering gauge looks like a pretty good option. It looks very similar to the Lindsey Racing one that I mentioned.

Do you know the size of the DG-210? Probably 52mm or 60mm, but it doesn't say.

Keep us posted on your progress.

[Kanaljen]

Ended up buying the sp engineering one.

Several reasons:
- The other one (DG 210) was not $180 but $310!

- The DG 210 would be harder to mount (I already have three gauges in the spot under the climate controls. I am thinking about mounting the sp engineering one in ashtray area since it's only 2.5x1x1, together with my Valentine 1 remote unit.

- The DG 210 did NOT have the external switching capability as one site said.. :( So I might just connect the heat exchanger fan to the the OEM fan via a relay.. Or, maybe just have it on if the engine is on.. Would be nice to find a way to have it shut off automatically at speeds over 30mph though..

- The DG 210 was out of stock and I couldn't get a date..

- I liked the idea to have the difference between pre and post intercooler air temp displayed.