Sucks about that leak, ouch. The temp delta is outstanding compared to A2A, I hope it's not the leak. I don't let that WOT sway me, I think the exchanger is way undersized ATM. Maybe
@Asbjorn could help get a sizeable (area) core made.
I don't think the fan has a check, dealer has left mine completely unplugged before and never got a light, even to the point of near overheating months later in traffic when it finally got warm out. I don't remember if the WP has a start check, but the thermostat does.
@Hydra Performance pointed out a tiny Arduino controller for standalone water pump with feedback controls for OE electric WPs, but not sure if all of those pumps are needlessly large in size or volume. I imagine it would probably operate any PWM electric pump at a basic level though.
This project is awesome. I've been reticent to switch to hot side inlets, but if enough pieces come together (outlets/exchanger would probably be the largest hurdles for most), I'd be more inclined to start ripping things apart.
@RSL good find!
One note on that *C temperature delta: it is (IAT - ambient).
That table was buried in there like a tick, geez. Never would've found it without help. Correct, IAT diff to ambient, which means some dialing in to find that sweet spot for the first break point between increased IAT when stopped and dropped IAT when moving. It will probably need some adjustment in seasons and doesn't have the light switch response like VS would (takes time for IATs to move up/down between stop/go), but does produce the intended effect.
@NoQuarter not sure you would get the fan to run 100% without supplying consistent 12v to the PWM channel on the fan, but I've never tried. It sounds like the ground test confirms that, but there are manual switch/fixed DC settings in the rom somewhere too.