[sagarpadaki]

Great job!
Was the stock intercooler inadequate to provide you with the required gains? Was any analysis done on the stock intercooler limits before deciding to install the bigger one?

What intercooler have you used? Stock of some car or aftermarket?

[CannedShroud]

Originally Posted by sagarpadaki

Great job!
Was the stock intercooler inadequate to provide you with the required gains? Was any analysis done on the stock intercooler limits before deciding to install the bigger one?

What intercooler have you used? Stock of some car or aftermarket?

Hey, thanks. Yes. The stock intercooler would heat soak very easily. And it being a turbo petrol would dial back timings tremendously to prevent knock.

I have seen IATs of around 60-70 degrees under normal pulls, that too in the evening runs. The car would feel absolutely lethargic once the heat got in and wouldn't like to move. The new intercooler locks down the IATs to 15-17 degrees around ambient. Which is amazing. Although it isn't in the most ideal conditions (being close to the condenser due to the packaging, it ends up picking some of that heat) - it still performs far better than the stock side mount.

This new intercooler is a 180bhp unit from Behr Mahle. It's a tube fin design that's not a OEM fit but is used by EE for other builds like the Creta and the Verna. It's not a OE intercooler.

I believe the same figures could definitely be achieved on the stock intercooler but not for long. Especially with this tiny turbo, it heats up the air a lot when spinning its heart out, this means even if you see boost (pressure) the air density decreases due to heat - so ultimately the amount of oxygen that ends up in the cylinders is less.

Definitely a recommended upgrade, and one that is noticable on this engine. Not in terms of peak performance - but rather consistent performance

[scorpian]

Congratulations on your stage 2 build. I wish you loads of happy pulls.
Party kena re?

[Piech_vRS]

The work done by the guys at EE is commendable. I can only imagine what A riot that car must be to drive, I was once behind the wheel of a N/A Altroz, and the first thing I noticed was how sorted the dynamics of the car were. And now with the stage 2 tune the car must feel complete.

And if you don't mind asking, What device did you use to click those pictures? The images have turned out be really sharp and clear. Asking just out of curiosity.

Enjoy Your Build!

[100Kmphormore]

Very nice job man. The Altroz iTurbo deserves a 150 hp/250 Nm tune just because of its suspension that makes the handling a dream - a corner rocket yet so good on bad roads. Yes, even beating the 2nd gen Swift. Please get your car viewed by Bhavneet of TDH (not that other boy), would love to hear that car with a full system Borla exhaust.

[svsantosh]

Just curious - how much is the surface area L*B*thk difference between the stock IC and the upgraded IC? The MOC (Alu) in both is the same, only the volumetric efficiency is different here (with a small compromise in the AC condenser being blocked now in hindsight).

I feel that had very little to do in the stage 2 mod, you may have gotten away with the DeCat & ReMap and achieved nearly the same.

I saw some previous posts here. The brake upgrade was cool. Now with this extra power - see if you can get hold of slotted/drilled rotors of the same dimensions to loose heat faster. I am sure some companies have them.

[CannedShroud]

Originally Posted by scorpian

Congratulations on your stage 2 build. I wish you loads of happy pulls.
Party kena re?

Thanks a lot bhai! Yaa mare

Originally Posted by Piech_vRS

The work done by the guys at EE is commendable. I can only imagine what A riot that car must be to drive, I was once behind the wheel of a N/A Altroz, and the first thing I noticed was how sorted the dynamics of the car were. And now with the stage 2 tune the car must feel complete.

Thanks a lot! The team at EE is absolutely amazing and it was possible only because of their genius and hard work! The chassis finally feels it has the power it deserves, maybe a bit more wont harm!

Next up will be stiffer and more progressive springs from the Racer - while maintaining the OE ride height!

Originally Posted by Piech_vRS

And if you don't mind asking, What device did you use to click those pictures? The images have turned out be really sharp and clear. Asking just out of curiosity.

Thanks again! All the images were clicked from my trusty Google Pixel 7 Pro. Google camera science never disappoints!

Originally Posted by 100Kmphormore

Very nice job man. The Altroz iTurbo deserves a 150 hp/250 Nm tune just because of its suspension that makes the handling a dream - a corner rocket yet so good on bad roads. Yes, even beating the 2nd gen Swift. Please get your car viewed by Bhavneet of TDH (not that other boy), would love to hear that car with a full system Borla exhaust.

Thanks a lot for your kind words! I actually had reverted back to the stock exhaust setup for the roadtrip to keep away from any cop trouble on the way. Might get a bigger resonator and a nice borla endcan down the road that has character but is not very loud.

I am not sure how this review thing works, and the fact that I am based on Goa means probably that is may be a far fetched idea. But the option is definitely welcome!

Originally Posted by svsantosh

Just curious - how much is the surface area L*B*thk difference between the stock IC and the upgraded IC? The MOC (Alu) in both is the same, only the volumetric efficiency is different here (with a small compromise in the AC condenser being blocked now in hindsight).

I feel that had very little to do in the stage 2 mod, you may have gotten away with the DeCat & ReMap and achieved nearly the same.

You are absolutely right! The intercooler would still hold the same boost, we are just making around 14 odd psi at max boost, plus the same intercooler is shared with the Diesel variant of the Altroz which runs higher boost. So the intercooler can hold the boost targets currently set - no doubt

But the point of the intercooler was to attain the power consistently over time. Being in Goa, days except for peak winter are usually hot - And the stock intercooler in the car would heatsoak very easily because the IATs would reach around 60-70 degrees. I kept an eye on them using a trusty WiFi based ELM ODB Dongle using the Torque App. Also, the intake of the Altroz being placed in an awkward spot with tight clearance from the bonnet meant that even the air filter would unfortunately suck in hot ambient air from the engine bay rather than fresh air from outside.

I don't have the exact measurements from both the intercoolers but I did to some rough checks - The stock one is 280x170x70mm. While the upgraded one is 540x170x50mm. Based on sheer volume, the newer one is about 35% larger than the stock one. But the key idea is the frontal area that the intercooler gets for fresh air is almost double! This means that even though the total volume might just be 35% larger, there is a lot more air coming to the intercooler. Plus to add to the benefits, because the intercooler is now practically a part of the condenser - radiator sandwich, the radiator fan also cools the intercooler in traffic!

I had a scenario on my drive back home, the roads just before manglore are completely broken because of construction work. There was basically bumper to bumper traffic with 40-42 degrees of costal heat. Even with such a scenario, the max IAT seen was about 59 degrees! And that dropped rapidly to a healthy 54 once we got moving.

The one downside I see to this setup is that it gets slight heat from the hot condenser - which means the IATs don't drop below 43-45 degrees even at night when ambient is 29 or so. But even then at around 15-18 degrees around ambient is usually deemed good for an intercooler.

But again, circling back to your point.. Would these numbers be possible on the stock intercooler? absolutely. But I would still spend the money on a FMIC just to get consistent power.

Originally Posted by svsantosh

I saw some previous posts here. The brake upgrade was cool. Now with this extra power - see if you can get hold of slotted/drilled rotors of the same dimensions to loose heat faster. I am sure some companies have them.

Thanks a lot, Please do reach out on private chat or drop any leads here which you have come across for this. I have been doing a lot of digging but unfortunately don't seem to find any options that are reasonable.

Thanks!