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Forum thread: Intercooler Fan Replacement - cheap alternative to OEM

clubsmartcar.com/index.php · p. 1 · Applies to: unknown

Source: clubsmartcar.com Topic: intercooler fan replacement Models discussed: unknown Language: en Solution status: yes

Problem: Intercooler fan failure causing high intake air temperatures (IAT ~120C on hot days), with OEM replacement cost inflated to over $400. High intake temps may contribute to intake manifold failure on plastic manifolds.

Solution: Mounted an Amazon 5" radiator fan on a 3D printed PETG bracket as a cheap aftermarket alternative. Testing showed IAT reduced to 69C on continuous hillclimb at 25C ambient (vs. 120C+ previously).

Key facts: - OEM intercooler fan cost increased from ~$180 to over $400 - High IAT temperatures (120C) observed on hot days under boost, potentially causing plastic intake manifold failure - 5" Amazon radiator fan mounted via 3D printed PETG bracket reduced IAT to 69C during highway hillclimb testing - PETG bracket rated for temporary operation at 60-70C; author considering polycarbonate/polypropylene for production if interest exists - 7" fan too large; 6" fan may be next iteration to test