Intercooler/Radiator

It has been known for some time that the standard Vectra VXR Intercooler works very effectively in both standard and Stage One application. However, to explain our development a little further, we have detailed some of our findings below which have allowed us to take what we feel is the strategic approach with excellent results.

After having developed both the intercooler and water radiator, with further testing over 4000 miles and in varying temperatures, it became apparent that although the inlet air temps had been reduced (and were shown to be excellent and stable), the water temperature was actually more significant to the car’s sustained performance than that of the intercooler, even in day to day running. This finding changed our development cycle to concentrate further efforts on the water radiator and the ancillaries.

Our further investigations found that the “turbo water return pipe” was placing super heated water directly into the expansion tank (we are sure you have seen a glowing orange turbo). This super heated water is in turn being fed back into the engine block. By developing a modified return feed to the expansion tank (still using the original feeds but re plumbed), temperatures of the water were reduced to those of the water radiator and not super heated from the turbo itself. This development has ensured that the recovery time of the water, after high speed driving, is reduced significantly. Also during constant and steady motorway driving the water temperatures stabilised at between 87-89 degrees. Furthermore the engine warms up from cold at the same rate, until the thermostat opens and then the water is regulated by the larger water radiator and special expansion tank return.

By developing the water radiator as a primary component, and to ensure that in day to day driving the water temperatures are kept as low as possible in the confines of the thermostat, once high power outputs are released then these can be supported with the confidence of reliable sustained performance. Furthermore, we consider that for a stage one re-map the water radiator benefits the car significantly more than the intercooler does on its own, after all there is little point in having an engine package with a thumping great intercooler resulting in 150% efficiency on inlet air temperature and only 80% efficiency on water temperature.

As standard cars run high water temperatures, owners of these cars are also likely to benefit from the reduced the water temperatures, resulting in more sustained performance levels.

However, in reverting back to our original strategy, our findings have also concluded, that higher power outputs WILL require the new intercooler, to ensure that inlet air temperatures are kept at the reduced levels that allow sustained performance, especially with the new turbo options now available for further development on the Vectra VXR.

The intercooler has been moved to the front of the car (in front of the air conditioning radiator) and is a full width and height, with a core twice the size of the original component. Fixings have been made to accommodate the air conditioning radiator on the rear, therefore requiring no additional pipe work replacement. All the original pipe work has been retained in its original position, to allow ease of fixing and the development of silicone hoses, where a special set will not be required just for the intercooler (this keeps cost down for the owner).

The Water radiator is enlarged both in height and depth it has more efficient core complete with alloy end tanks and retains the original fixing for the all pipe work and the fans.