Road damage to intercooler

The fins provide cooling and they should be combed straight, with a radiator "fin comb". It's "ok" if they aren't all straight, but you want them all as straight if possible. Same on an a/c condenser, radiator, intercooler, etc. JB weld is probably the best DIY fix, but you could have it spot welded. Is it leaking?

That can't be good!

AcesandEights

The fins provide cooling and they should be combed straight, with a radiator "fin comb". It's "ok" if they aren't all straight, but you want them all as straight if possible. Same on an a/c condenser, radiator, intercooler, etc. JB weld is probably the best DIY fix, but you could have it spot welded. Is it leaking?

I'm not sure if it's leaking. I'm not sure how to tell. It just looks like in one spot there is a puncture. My thinking is I would just want to block out water and dust. I get what you're saying about the aluminum fins being straight as possible. I'm asking about the Black plastic ones that go side to side. They are all broken out on the one side.

i work in the heating and cooling industry building chillers your intercooler is fine with damage to the fins like that its no big deal the fins only help dissipate heat transfer with the air flow flowing over the coil that is behind the fins but if there is a true puncture past the fins and into the coil then you have an issue but it doesn't look like it was that bad and you can just get a condenser fin comb and straighten those fins for aesthetics.

95'/21' BRONCO BOI

i work in the heating and cooling industry building chillers your intercooler is fine with damage to the fins like that its no big deal the fins only help dissipate heat transfer with the air flow flowing over the coil that is behind the fins but if there is a true puncture past the fins and into the coil then you have an issue but it doesn't look like it was that bad and you can just get a condenser fin comb and straighten those fins for aesthetics.

^ THIS

Now I need to go take a close look at the front of my Bronco - it may be time to fabricate some mesh guards/screens to protect this vulnerable part.

Here is my JKU with some mesh that I installed to protect the radiator (and it looks cool too)

A

dirty finger

I'm not sure if it's leaking. I'm not sure how to tell. It just looks like in one spot there is a puncture. My thinking is I would just want to block out water and dust. I get what you're saying about the aluminum fins being straight as possible. I'm asking about the Black plastic ones that go side to side. They are all broken out on the one side.

Are you talking about the louvers in front of it that open and close?

It looks like there is a hole in it where the air passes through. I'm not sure if dirt will get in here and end up in your motor. I'm new to intercoolers and not sure exactly how the air goes through everything.

SlashRacer

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Are you talking about the louvers in front of it that open and close?

yes! Thank you! That the word. Louvers!

SlashRacer

It looks like there is a hole in it where the air passes through. I'm not sure if dirt will get in here and end up in your motor. I'm new to intercoolers and not sure exactly how the air goes through everything.

View attachment 22241

That's what I'm worried about. Dirt and water getting in there. So, for now I just put some JB Weld in there.

dirty finger

That's what I'm worried about. Dirt and water getting in there. So, for now I just put some JB Weld in there.

It looks like you have it plugged. But…….I would still take it in and get a quote to have intercooler and the louvers replaced. Then decide if you want your insurance to pay for it and have it fixed.

SlashRacer

It looks like there is a hole in it where the air passes through. I'm not sure if dirt will get in here and end up in your motor. I'm new to intercoolers and not sure exactly how the air goes through everything.

View attachment 22241

I cringe every time I see it...

Now might be a good time for a charge air cooler upgrade. I think they are a few weeks out still but probably will be cheaper than replacing with OEM parts.

Jakob1972

Now might be a good time for a charge air cooler upgrade. I think they are a few weeks out still but probably will be cheaper than replacing with OEM parts.

I think you're right. I'm hoping that the JB weld will hold long enough to upgrade. I just don't fully understand the role of the louvers. Is there any harm in not having louvers on that side?

I wouldn’t worry very much about dirt getting IN, I would worry about air getting OUT.
The intercooler accepts pressurized air from the turbo. With a hole in it, this air is going to leak out, meaning that you won’t get enough boost.

dirty finger

I think you're right. I'm hoping that the JB weld will hold long enough to upgrade. I just don't fully understand the role of the louvers. Is there any harm in not having louvers on that side?

They close when it's cold to help the engine reach operating temp faster. It helps with efficiency, but not a critical operation. At least, that's how they work on my '74 International and my '21 GMC, I don't have my Bronco yet but assume that's what they do.
As for the hole in your intercooler, the JB weld was IMO a good short term solution. The intercooler is on the charged air side of the system, after the turbo, so it has positive pressure and would have been blowing air out of that hole under load. That would most likely keep the bulk of dirt out of the system (not all), but the loss of pressure would cause a distinct loss of engine power under load. I agree with others you should start looking at aftermarket upgrades vs. a stock replacement, but take your time to research it a little and find the right one.

dirty finger

Jakob1972

Now might be a good time for a charge air cooler upgrade. I think they are a few weeks out still but probably will be cheaper than replacing with OEM parts.

I think you're right. I'm hoping that the JB weld will hold long enough to upgrade. I just don't fully understand the role of the louvers. Is there any harm in not having louvers on that side?

The Louvers are part of the active airflow system covering the Intercooler and radiator. The Bronco actively opens and closes them to optimize cooling vs fuel efficiency. It opens the plastic louvers to allow airflow for cooling and closes them when cooling isn’t needed to improve aerodynamic flow. You will be ok without them, but I don’t see why you wouldn’t submit an insurance claim to fix them and replace the intercooler.

While dust and water in the intercooler probably isn’t great… someone above was correct when they said that the larger concern is that it’s a pressurized system, so if air is leaking out you will not only have worse cooling of the turbo air, you will be unable to build up as much turbo pressure, which will lower engine output and tax the system overall.

If you are set on not replacing it, you can check the seal on the JB weld by running the engine and while in park or neutral, have someone throttle up (and watch the turbo psi gauge) to build up some turbo boost. While they’re doing that,pour soapy water around the hole and bent fins and watch for bubbles/spitting.

I have made this repair on a Mack truck intercooler. If it looks punctured assume it is . I used JB weld. I t lasted for 5 years and counting. Clean and dry is the operative words . It will work fine. The turbo produces very little pressure. A small hole make it even lower. You can also use an acetate glue like crazy glue mixed with baking soda will make a putty like adhesive that can be sanded.

dsnow58

If you are set on not replacing it, you can check the seal on the JB weld by running the engine and while in park or neutral, have someone throttle up (and watch the turbo psi gauge) to build up some turbo boost. While they’re doing that,pour soapy water around the hole and bent fins and watch for bubbles/spitting.

You may not be able to build enough boost with the engine unloaded. My old Fummins only builds 1-2 psi unloaded and my 2020 2.0t equinox will not build boost unless rolling. It won’t even let me do a boosted take off. Best way to check it would be to get a boost gauge and see if it reaches maximum boost while pulling a hill if it is less than you have a leak. I wish these new turbo vehicles all came with boost gauges I would figure these turbos would push about 10 psi, might be different between the 2.3 and 2.7 also.