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Discussion Starter · #1 ·
Hi,

I found out by accident while i was tampering with the car [as usual
] that my intercooler was damaged, i must have hit a bird or a stone or something... It doesn't look fresh, and i haven't noticed any boost loss or anything like wise, but it's annoying me and i would like to get it changed...



I've been searching the web for an alternative for the stock intercooler and have found some interesting ones, some more expensive than others, and would like to know what is the difference between brand name intercoolers /FORGE, EVOLVE, HEICO...ect./ and other makes that seem to be quality built too but at 20% the price of the brand name.

examples>

THIS ONE for example would fit just fine, so would THIS ONE

And there are many out there being universal/generic with the correct dimensions for cheap, i mean the basic thing is for it to be made out of a non-rusting alloy, and for my 136bhp engine i think they wouldn't do any harm, OR would they?

Need some advise on this please, do these intercoolers differ in internal structure?

btw, i would love to get the Focus ST intercooler but it's too high and would be hidden behind the front bumber beam so no point in that, but still, price wise, it would be cheaper than a Forge or Evolve intercooler.

any help appreciated
 

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You should check any intercooler to make sure it has a mounting spot for the volvo intake air temp sensor. I know the bell did when I installed it.

http://www.bellintercoolers.com/pages/S40Main.html
Look at the pic; at the very left side of the IC, by the outlet, there's a big hole and a little hole. The sensor fits there.

The bell requires trimming your bumper a bit, but i did that with a dremel tool pretty easily.
 

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I'd say the ATP one would be the way to go for you, since everyone who has gotten it says they like it. I am still waiting on getting one, hopefully going a more custom route, but I am going to do all of my major performance upgrades at the same time: 3" downpipe, intercooler, turbo upgrade, etc. so I don't have to get remaps and can be blown away by the difference in performance.
Good luck in your search, people on here that actually have an upgraded intercooler can chime in for more beneficial info.
 

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Discussion Starter · #4 ·
Re: (carreragt7)

Thank you guys for your input!

mattdoc> i think, but not quite sure yet, that the intake air temp sensor on the 2.0D is built in to the intercooler hose, and not in the IC frame or body, i'll have to check first to verify, but i don't remember seeing any sensors attached to the IC frame on the outlet side...

The Bell IC seems like a solid build, but it is for the T5 engine only as i have seen, so i guess i'll have to keep looking.

carreragt7> Do u mean Garret IC's? I can't seem to find an ATP dedicated web site. btw, good luck on your upgrades! http://********************/smile/emthup.gif

regards
 

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Re: (Guru)

Website is ATPturbo.com

They are using Garrett 350whp intercoolers and making to fit with custom endpipes. Thats the kicker the intercooler has to have the custom length endtanks/pipes in order for the factory couplers to attach.

The generics can work but will require welding and modifications to fit. I recommend going with a reputable name for the core as that is what the majority of the performance from the intercooler relies on. Ebay generic cores have a cheap core with minimal fins which is the basis of transfering the intake heat.

Im going custom as its hundreds cheaper than the aftermarket and will yield the same results.
 

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Re: Differences between intercoolers? (Guru)

i have the evolve one and i love it. quality is great and was a direct replacement with out cutting or anything. http://********************/smile/emthup.gif
 

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Discussion Starter · #9 ·
Re: (ForceFed Motorsports)

Excellent! thanks for the info.

Quote, originally posted by ForceFed Motorsports »
Ebay generic cores have a cheap core with minimal fins which is the basis of transfering the intake heat.

Some of those generics advertise 6 fin IC's and 100% aluminium structure, so do you know what number of fins is a sufficient number for adequate heat transfer?
 

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Re: (Guru)

Its all about fin density and although people will tell you otherwise front surface area is greater than overall surface area. A taller IC with the same surface area as a shorter thicker IC is better. Have to realize as the air passes thru the IC to cool the fins its going to warm up not drawing out the heat from the back of the IC as effeciently as the front.

Mine is 8" tall and 3.5" thick im working on and got to fit just fine. If you want to compare core density ill post some pics of the difference.



This is a treadstone core which are fairly reputable, compare that to the cores from ebay and you will be able to tell the difference.
 

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Discussion Starter · #11 ·
Re: (ForceFed Motorsports)

Thank you ForceFed, you've been of great help to me http://********************/smile/emthup.gif dimension of mine without the need to modify anything are 24" x 5.6" x 2"

I understand the physics of the subjects perfectly, although a very few advertisers on e-bay show pics of the core, so it's not easy to compare densities without actually seeing in person, but i'll try to make that special request by e-mailing the sellers and see what pics they'll send, if any.

btw, have you ever tried spraying you IC with cold water using a garden hose before going for a fast ride?
the boost almost doubles, and you can really feel the G's! seen people redirect their headlamp washer toward the IC for this effect... it really does work!
 

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Re: (genjy)

My integra had it... used plant squirters in front of the intercooler up underneath the bumper. Rerouted the lines for my windshield squirters to them and would fill up my windsheild resevior with water and ice cubes. I could roll up in the staging lanes and just have to pull my sprayer lever and hose my IC down before a run. Just be careful at the track since getting water or anything can get you booted back to tech inspection if they think you are leaking anything.... ask me how i know lol.
 

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Discussion Starter · #14 ·
Re: (ForceFed Motorsports)

Quote, originally posted by ForceFed Motorsports »
ask me how i know lol.

How do you know? lol


I found that out by accident btw, after washing the car and hosing down the IC's front surface from bugs and insects, i went for a drive and the boost was awesome. http://********************/smile/emthup.gif

I'm not quite in to tracks, nor do i race, i just do sunday morning test drive solo sprints in the country side while the traffic police are still asleep and speed radars are turned off...


It's a pitty you don't have these TD Volvos in the states, i'm sure you'd love them, stock torque is 340Nm at 2000rpm and aprox. 140hp under the hood, easily upgradable to 170hp, besides it's not a dirty noisy black smoking diesel like diesel cars from the past, the engine is very refined and the sound is so smooth you wouldn't believe it's a diesel, and the 40mpg combined urban+extra urban is also very pleasing http://********************/smile/emthup.gif

regards. http://********************/smile/emthup.gif
 

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Re: Differences between intercoolers? (Guru)

http://www.atpturbo.com/Mercha...=VC30



The ATP IC baffles me. Why on earth is there such long piping when they could have had more surface area. It looks like they retrofitted something that would fit rather than choosing the best design available. Evolve has done the same thing. Only Bell seems to have actually leveraged the entire grill opening.
 

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Re: Differences between intercoolers? (uv23)

Thats because like i stated ATP's is a garrett 350hp rated intercooler, just like the ones you find if googled as they are a supplier. What they did was just pull one off the shelf and modify it to fit the S40. The core isnt as large as some of the others but thats where Garretts higher quality comes into play as the results are more than likely the same.
 
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