A condensed water discharge apparatus in an engine of a vehicle provided with a water cooling type intercooler installed integrally with an intake manifold includes a body provided on the intake manifold and having a designated receipt space formed therein to store condensed water generated by the intercooler and a discharge hole formed in the receipt space to discharge the condensed water stored in the receipt space to the outside through the discharge hole; a discharge valve configured to open and close the discharge hole; and an operating unit connected to the discharge valve to operate the discharge valve.

An intercooler may include a condensate collector configured to collect condensate precipitated in the intercooler. The condensate collector may be separate from the intercooler and disposed below the intercooler. The condensate collector may include at least one expansion chamber, the at least one expansion chamber arranged above an inlet and an outlet of the condensate collector during operation of the intercooler.

Methods and systems are provided for increasing airflow through a charge air cooler (CAC) in order to purge condensate from the CAC. In one example, a method includes increasing airflow through the CAC while maintaining torque by selectively deactivating one or more engine cylinders and increasing boost. The number of deactivated cylinders may be based on an amount of condensate within the CAC.

Methods and systems are provided for estimating water storage in a charge air cooler (CAC). In one example, an amount of water in charge air exiting the CAC may be based on an output of an oxygen sensor positioned downstream of the CAC. Further, engine actuators may be adjusted to increase combustion stability and/or reduce condensate formation based on the amount of water exiting the CAC.

A liquid drain valve assembly for a charge air cooler includes a valve housing configured to couple to the charge air cooler, the valve housing having a condensate inlet configured to receive condensate from the charge air cooler, and a condensate outlet. A valve is disposed within the valve housing. The valve includes a diaphragm seated against an inner wall of the valve housing and movable between a first position enabling condensate to flow past the diaphragm and out the condensate outlet to selectively drain condensate from the charge air cooler when the charge air cooler is not in a boosted condition, and a second position preventing condensate flow out the condensate outlet when the charge air cooler is in a boosted condition to thereby isolate the charge air cooler from the atmosphere.

A turbocharging system for use with an internal combustion engine, which includes an exhaust gas feeding passage configured to feed exhaust gas of an internal combustion engine to a turbine unit; an exhaust gas passage configured to release the exhaust gas discharged from the turbine unit outside of the turbocharging system; an intake air passage configured to feed intake air into the compressor unit; a compressed air passage configured to feed compressed air discharged from the compressor unit to the internal combustion engine; an intercooler configured to cool the compressed air flowing through the compressed air passage; and an LPL-EGR passage configured to recirculate at least a part of the exhaust gas flowing through the exhaust gas passage, into the intake air passage, wherein the compressed air passage is provided with a cyclone-type collecting device arranged upstream of the intercooler to collect foreign substances contained in the compressed air.

Methods and systems are provided for cleaning a water-cooled charge-air cooler. In one example, a method may include condensing water present in the supplied charge-air and exhaust gas which may exist in gaseous and droplet form, and purging the condensate along with the exhaust gas. A system for carrying out the above mentioned method is also provided.

Methods are provided for controlling a vehicle engine to improve engine efficiency utilizing onboard water condensate. In one example, condensate is collected from cooling air routed into an engine, and injected into one of a plurality of locations based on engine operating conditions to keep NOx in combustion gases below desired amounts and to avoid ignition knock in said engine. In this way, condensate build-up in the CAC is advantageously utilized, engine performance and efficiency may be improved, and harmful emissions may be reduced.

An integral drain assembly for a heat exchanger includes a plurality of passage walls defining a plurality of passages, each of the passage walls having a non-linear portion. Also included is a drain wall integrally formed with at least one of the passage walls to define a drain for each of the plurality of passages, the drain wall located proximate the non-linear portion of each of the plurality of passage walls.

Methods and systems are provided for estimating water storage in a charge air cooler (CAC). In one example, an amount of water accumulating in the CAC may be based on an output of an oxygen sensor positioned downstream of the CAC and ambient humidity. Further, engine actuators may be adjusted to purge condensate from the CAC and/or reduce condensate formation based on the amount of water inside the CAC.