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Old 5th March 2016, 17:24   #16
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Default Re: DIY: Cleaning the Intercooler

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Originally Posted by VeyronSuperSprt View Post
DO NOT work under a car by placing it on a jack. Always place the car on a jack stand (two ideally in this case). It can be extremely hazardous if the jack slips / gives way (for the car and the individual).
I agree but as seen in the picture I didn't lift the car at all.

As I parked the car in reverse direction in my garage, there is a minor slope so what I did was parked it on flt ground just before the start of the slope. This made enough space below the front bumper to work on.

DIY: Cleaning the Intercooler-dsc02669.jpg

The above picture will give you an idea regarding the gradient of the slope that I am talking about.

PS: Thank you for the suggestion. I agree fully.

PPS: I have bought a pair of Jack stand from SnapDeal. Awaiting delivery.
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Old 5th March 2016, 18:07   #17
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Default Re: DIY: Cleaning the Intercooler

^^
Anurag Bhai, the driveway/parking is currently dug up for sewer work hence I am going to the FNG guy for the work. Moreover, there is a laundry list of pending work(brake pad change, blown Fogs, WA/WB, Fluid replacement/75K service). It will be a fun day tomorrow, working with air-tools
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Old 5th March 2016, 18:55   #18
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Default Re: DIY: Cleaning the Intercooler

Wonderful Job Anurag. A very useful DIY for the DDiS engines. Or rather, most of the turbo engines with oil cooled turbos.
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  1. While refitting the clamps, be careful to not over tight them or else they'll crack, leaking pressure and loosing engine power.
The turbo hose clamps need to be tightened really well. Or else, when the boost builds up, they just pop off.
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At the end of the day, post the cleaning, the heat exchanging would be better and air getting into the engine would be cooler than what it used to go. So there would be marginal increase in performance and Fuel efficiency.
In fact the real reason for the Intercooler Cleaning for vehicles with Oil Cooled Turbo is that, however perfect or new the turbo oil seal is, some amount of oil seeps into the intake side (intercooler and intake plumbing). Also oil comes from the PCV. Because of this, the intercooler gets clogged. Resulting in a serious drop in performance.

If it was really time to clean your intercooler, you would've noticed a considerable amount of performance difference. Especially the with the turbo lag. But then, its a very good practice to clean the intercooler every ~30-40k kms. In older vehicles every ~20k kms.
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Old 6th March 2016, 09:07   #19
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Default Re: DIY: Cleaning the Intercooler

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Originally Posted by a4anurag View Post
...

Also this is the first time the intercooler is being opened in the 72,000 kms that the car has clocked...
1st time in 70k KMs?

The service centre advised me to get it done on every service (10k KM), but I decided against it & I get it done every 20k KMs now.

PS: My car is a Dzire ZDi 2013 model.
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Old 6th March 2016, 09:13   #20
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Originally Posted by ank.nsit View Post
1st time in 70k KMs?
Yes 1st time. Never got it done though I was billed once but they refunded the amount. Actually never felt the need for cleaning. Same goes for EGR cleaning too.

This DIY attempt was just my curious side to see what was the quantity of oil collected.

Last edited by a4anurag : 6th March 2016 at 09:15.
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Old 6th March 2016, 10:07   #21
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Default Re: DIY: Cleaning the Intercooler

Amazing DIY Anuraag. Looking at the pictures make me realise what a car and more importantly an engine has to go through in India. I have a 5k done 3 month old Mazda 3 here in Australia and although I pressure wash my car regularly, the radiator fins are a stark contrast. They are still dust free and all that I can find on them are bugs from the highway drives.

There is no more fun than cleaning your car yourself. I hope it helps the people on the forum to do it to their rides.
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Old 7th March 2016, 08:58   #22
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Default Re: DIY: Cleaning the Intercooler

Very detailed DIY Anurag . One more to your never ending thirst for DIYs.

Its 85,000 on my Ertiga and I have got the Intercooler cleaned as part of the periodic service only once, at 50,000 kms on the ODO. Since I stay with the car when things are attended, I noticed absolutely nothing at all when it was washed and the drained. Everything was as before even after the cleaning.

Due to this, I decided that I will clean the intercooler only on need basis and not really every 20,000 kms. However the story wasn't the same with EGR that MSIL recommends to clean every 30,000 kms. I got it cleaned first time at 82,000 kms and it was indeed clogged. Post cleaning, even though there is a mild difference in terms of the way the vehicle performs and the difference in FE, I am careful not to mention that now as the sample is only 3000 kms after cleaning.

I have taken up only 2 highway drives in those 3000 kms with rest being office drives and can easily notice a difference in FE even at good cruising speeds and full load but I will have to wait and watch for more before I confidently say that the difference was due to EGR cleaning.
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Old 7th March 2016, 09:48   #23
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Default Re: DIY: Cleaning the Intercooler

That is a very thorough cleaning done Anurag. No service center would do this level of cleaning. Job well done?

My i20 diesel has never undergone a Intercooler clean nor does Hyundai mention anything about it in the User Manual. How to know if i need to get the IC cleaned?
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Old 7th March 2016, 12:25   #24
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Default Re: DIY: Cleaning the Intercooler

Thanks Anurag for this wonderful DIY. This month I have 2 things in my list.

1. Get the coolant recharged.
2. Get the intercooler and radiator cleaned.

Is the process to get to the intercooler same for VVT also ?
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Old 7th March 2016, 13:10   #25
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Originally Posted by sagarpadaki View Post
How to know if i need to get the IC cleaned?
Many say that if the oil consumption is high and the car isn't performing well, the cleaning of the intercooler must be done. That essentially drains the oil out and make the intercooler perform better.

I never had any indications or symptoms prompting me to clean the intercooler. I did this because I was curious.

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Is the process to get to the intercooler same for VVT also ?
You have a petrol i20, right?
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Old 7th March 2016, 14:24   #26
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Quote:
Originally Posted by a4anurag View Post
Many say that if the oil consumption is high and the car isn't performing well, the cleaning of the intercooler must be done. That essentially drains the oil out and make the intercooler perform better.

I never had any indications or symptoms prompting me to clean the intercooler. I did this because I was curious.



You have a petrol i20, right?
Petrol Dzire Anurag.
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Old 7th March 2016, 14:25   #27
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Default Re: DIY: Cleaning the Intercooler

NA petrol engines do not have intercooler. Only Turbo charged ones have it
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Old 7th March 2016, 15:40   #28
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Default Re: DIY: Cleaning the Intercooler

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NA petrol engines do not have intercooler. Only Turbo charged ones have it
.. blow me away. Is this a feature only on DDIS then or can petrol guys can do a after market fit !!!
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Old 7th March 2016, 15:49   #29
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.. blow me away. Is this a feature only on DDIS then or can petrol guys can do a after market fit !!!
Lol.

The intercooler is generally clubbed with the turbocharger.
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Old 7th March 2016, 19:50   #30
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Default Re: DIY: Cleaning the Intercooler

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Originally Posted by a4anurag View Post
Lol.

The intercooler is generally clubbed with the turbocharger.
In this case, can I get the original Intercooler + Turbo charger of Maruti and fix it on my VVT ? I see that the plumbing looks almost similar except for the condenser + radiator on my VVT is much bigger than the DDiS.

Is there a possibility !!! Looks very very tempting.
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