I admit I don't know much about intercoolers yet, but I discovered something called an EGR cooler, which cools the exhaust gases before they travel through the EGR valve back into the intake manifold.

This got me to thinking--people connect intercoolers between the turbo and the intake manifold--wouldn't it be simpler and easier to just remove the EGR valve and connect the intercooler to where the EGR valve used to be?

The intercooler would still be connected after the turbo, and the cool air should travel into the intake manifold without having to space out the turbo.

How likely is this to work?

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1967 W110 Universal Wagon, Euro, Turbo Diesel, Tail Fins, 4 Speed Manual Column Shift, A/C
1980 W116 300SD Turbo Diesel, DB479 Walnut Brown, Sunroof, Highly Optioned, 350,000+ Miles

You are talking about exhaust gases going back into the intake, little flow, not always flowing (depending on engine temperature, load,...).
An intercooler cools down the complete intake flow coming out of the compressor side of the turbo (fresh air). This air gets hot because of being compressed by the turbo.
Two different things.

Tom

The EGR would be removed completely, and all that would be left is a hole in the intake manifold (with the hole in the exhaust manifold plugged). So, I have been wondering if the cold air from the intercooler could just be plumbed into the EGR hole in the intake manifold instead of coming in from a pipe in between the turbo and intake manifold.

As I understand it, the intercooler should go after the turbo, correct? And if so, does it make a difference whether you route the air into a pipe between the turbo and intake manifold, or make it come in through the EGR hole? It seems to me like there would be no difference between the two, and that utilizing the EGR hole rather than going into a pipe between the turbo and intake manifold would be simpler.

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1967 W110 Universal Wagon, Euro, Turbo Diesel, Tail Fins, 4 Speed Manual Column Shift, A/C
1980 W116 300SD Turbo Diesel, DB479 Walnut Brown, Sunroof, Highly Optioned, 350,000+ Miles

where do you get the air from that you want to cool down and feed into the EGR hole in the intake tube?
Hopefully not from the exhaust, way too hot and low flow.
Imagine you have to cool the complete air flow through the intake what a small flow is behind your idea?

This has nothing to do with exhaust gases, though. This is simply putting in cool air into the intake manifold where the EGR valve used to be connected. I don't know exactly where the cold air comes from--from the intercooler itself, somehow.

But, my question is, wouldn't it be easier to instead of putting the cold air into a pipe between the turbo and intake manifold, to put the cold air into the hole where the EGR valve used to be?

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1967 W110 Universal Wagon, Euro, Turbo Diesel, Tail Fins, 4 Speed Manual Column Shift, A/C
1980 W116 300SD Turbo Diesel, DB479 Walnut Brown, Sunroof, Highly Optioned, 350,000+ Miles

No that won't work.

You should read up on how intercoolers work - you'll understand a lot more about how to plumb one up. Think of it like a radiator for the air coming from the turbo. Instead of coolant pipes going to the cylinder head and water pump you have one end going to the turbo and one end going to the intake. All engine air passes through the intercooler.



-J

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