To eliminate intercooler condensation, this straightforward solution makes use of manifold suction.
Ford has come up with a simple way to get rid of condensation that can form in the intercooler of a turbocharged engine under certain ambient conditions. The solution to this issue can be found in a fluid level sensor and some clever engine control programming, according to a patent that CarBuzz discovered at the United States Patent and Trademark Office (USPTO).
The fact of the matter is that the unintentional introduction of some water alongside the intake air occurs more frequently than you might think. You might not even have been aware that such a problem existed. Because they are typically mounted at a height that is comparable to the throttle body, air-to-water and top-mount air-to-air intercoolers are particularly susceptible to this issue. However, because their mountings and outlets are typically significantly lower than the throttle body, front-mounted intercoolers rarely pose a problem.
In a forced induction engine, a small amount of water mist in the air-fuel mixture may even improve performance and have no effect on combustion; however, swallowing a larger volume of water will be detrimental to combustion, effectively extinguishing the spark plug's flame. In extreme cases, excessive water intake will cause the engine to hydrolock, resulting in extensive engine damage.
Some Ford EcoBoost engines have misfired at idle and run rough when accelerating as a result of this issue. However, the issue can occur on any gas or diesel turbocharged engine with high boost pressure under certain environmental conditions and is not limited to Ford's boosted engines.The elevated boost pressure required to make a V6 engine perform like a V8 exacerbates the issue, making high ambient humidity a major contributor. Condensation forms more readily when the boost is increased because the saturation temperature of the compressed air decreases. Condensation in the intercooler will grow even more if the surrounding air is very cool and humid.
Owners of earlier Ford F-150 Raptor 3.5-liter V6 EcoBoost engines have reported intermittent misfires while cruising and stumbling while accelerating as a result of water droplets in the combustion chamber interfering with the process of combustion.
2021-2022 Ford F-150 Raptor Hood Ford's interim solution to these symptoms was to move an air deflector from the top to the bottom of the intercooler to increase heat in the cooler. This vaporized the condensation once more and allowed it to pass through the engine without causing problems. However, this is clearly counterproductive because it reduces the efficiency of the intercooler. The intercooler in later models has been redesigned to prevent condensation, but the fundamental issue remains.
This new patent offers a better solution that doesn't affect the efficiency of the intercooler in the same way that the previous fixes did. It involves reprogramming the engine control unit (ECU), a bypass passage from the intercooler's lowest point to the throttle body, and a fluid level sensor in the intercooler itself.
2021-2022 Ford F-150 Raptor Front Angle ViewCarBuzz When the sensor's signal tells the electronic control unit (ECU) that a predetermined level of condensation in the intercooler is approaching, the ECU will hold off slightly on the throttle until the engine reaches idling conditions. This will stabilize the engine's idle while it takes a sip of water by producing an air suction stream at the bypass passage outlet just after the throttle plate.
The suction stream controls the controlled movement of the accumulated condensation from the intercooler into the intake manifold. The small amount of water in the air-fuel mixture won't affect the combustion process if the condensation flow is controlled. The ECU will also turn on the glow plugs in a diesel engine to heat the combustion chamber and make it easier for water droplets to evaporate.
The Front View of the 2018-2019 Ford GTIn every instance, there will be an illuminated warning light in the instrument cluster to alert the driver that full performance may not be available while the intercooler drains. Normal operation will resume, and the warning light will go out on its own when the ECU receives a signal that condensation levels have decreased sufficiently.
Condensation in the intercooler is not a new phenomenon; however, this issue has only really become apparent in widespread use with ever-increasing boost pressure. Fortunately, the issue should be resolved with this new patent, allowing intercoolers to once again function as efficiently as possible without affecting the engine.
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