Intercooling Bosch injected, non-chargecooled engine
I decided that while I had my car apart chasing oil leaks, I would take the time to intercool the engine as well. The only viable option is water to air, as there is just no cool airflow near the engine to use. I don't want more power, just reliable / consistent power.
I started with a 24"x6"x2" heat exchanger stacked in front of the A/C condenser. I relocated the oil cooler a little further forward and standing straight up, then put the heat exchanger at an angle against the condenser. It is a tight fit, but it all goes in nicely. The water lines both exit the passenger side of the car. Technically I am mounting the heat exchanger upside down, so the "drain" is now a bleed vent. I created a remote bleed valve that hangs down below so that the front of the system can easily be bled.
I put the bosch water pump in the cavity in front of the passenger side front wheel. It pushes the water through the heat exchanger.
I ran two 1" aluminum pipes down the frame under the car. They tuck in nicely on either side of the frame between the frame and the body.
In the engine compartment there is alot going on. I will let a photo do the talking. I did a coolant bottle to act as a reservoir, plus a bleed line off the highest point into the coolant bottle to help self bleed as much as possible.
I sourced the parts from all over, if you have a specific question on source, just let me know. I also repainted my red stuff with VHT wrinkle red paint, then a 2 part clear coat.
I haven't driven the car yet, wiring in a old plxdevices wideband O2 sensor controller. It has a cool option of outputting a modified narrow band signal. Goal is to input from the wideband, modify the signal, output to the bosch ecu system. I can output that the car is running a touch lean, to trick the computer to give more gas.
The wideband actually has 2 outputs. Someone gave me the idea of connecting a relay to the full throttle switch. Instead of going to a fixed duty cycle for the frequency valve at full throttle, the relay can switch the O2 sensor output to the bosch computer to the modified signal and run closed loop full throttle with a modified signal to richen the mixture to my liking. Right now, I will just watch the meter to see what is going on, but it is nice to have a tuning option that doesn't cost $600 like the digital WUR.
1988 Lotus Esprit Turbo
2002 Lotus Esprit V8 25th Anniversary #008