Re: S4 rebuild, Intercooler temps

["Scott M." <scottmo@teleport.com>]

Malcolm,

> It was found on the rollers that the standard S4
intercooler isn't up to
> the job. Maybe not due to its construction, but that very
little air can
> get to pass through it due to its location and the
proximity of other
> rubbish i.e washer bottle etc. Fitting a larger IC may
not help. The
> intake charge was running around the 85-95 deg C on boost
which Aelred
> suggested was way high. Due to the heat, they restricted
the max boost
> at 1.2bar.
> snip> Also, any recommendations of temp
> gauge/thermistor to permanently monitor the charge temp?
Any other
> useful sensors I should invest in to keep an eye on
things in general?

To make the intercooler inlet/outlet air temp measurements,
you can get some K or J type thermocouple wire made up in
~12 foot lengths to run them from the intercooler to inside
the car for testing purposes, small diameter 30-36 gauge
wire is preferred for fast response. You can insert them
inside the intercooler pipe along side the rubber hose. The
temp sensing  end of the thermocouple wires are typically
welded together and a two pin connector is installed on the
opposite end when they are made.

Handheld thermometers are available in the US for $50-200
to connect the thermocouples into for measuring
temperatures. The more expensive versions can record
Min/Max temps and in some cases will display the delta
(T1-T2) to see the effect of the intercooler. 

I believe that Andial in Calif. also sells a dash mounted
setup for ~$225 to record inlet/outlet intercooler temps
along with the thermocouples. The exhaust gas temp gauges
available for $50-100 use the k type thermocouple as well,
but have a high temp metal sleeve to protect the wire.

Where are you located? Outside the US?

HTH
Scott Mo.