Why not just get the Genuine-MB intercooler, assuming yours is starting to fail for some reason? It can be had over at MBOemParts.com for just over US $200, about the same as the Mishimoto one.

I would first wonder why you're getting the heatsoak. I don't see that with our 2005 E320 CDI, so I figure there's got to be something else going on.

 

I wouldn't say excessive heat soak. We had an extremely hot summer here 100+. And I did a lot of commuting into NY city. I would say sitting in traffic you feel it when the car first starts to move.

I also have a tune on the car and the tuner said better to get an intercooler that is solid rather than the plastic end caps.

I'm not set on changing it out, just throwing it out there.

 

I've kind of been looking out for the same. Here's what I've found:

https://ecutuningkaunas.com/intercooler-450-hp-700x180x65-mm-27x7x2-55-inch/

VRP CDI Intercooler Kit W211 & W219 | VRP Speed

Upgrade your car's performance with the VRP CDI Intercooler Kit W211 & W219. Improve airflow, increase horsepower, perfect fit for W211 or W219.

www.vrpspeed.com

They're nearly the same in dimensions.

 

I have seen this kit floating around. It looks good, but is is just expensive. The

Mishimoto - 189
Elbows - 120 (you can find something cheaper if you shop around )
Claps - ~ 20
329

 

Ah, you've got a tune. OK, in that case, DieselBound's idea is a good one.

And yeah, those 100-degree days can have an effect. But bear in mind that if you're sitting in traffic a lot with not a lot of airflow, you might run into the same problem. Perhaps a fan of some sort just for the intercooler might help?

 

How about an intercooler mist sprayer?

Rabble rousing du jour - Do intercoolers heat soak more from ambient temp or use? Turbo output at 1 bar is 200-300F. Will Idling on a hot day get the intercooler to those temps?

Sixto
05 E320 wagon 212K miles

 

THE question is what does it take to mate up the connections to the car's plumbing. The VRP kit appears to be complete, don't know whether one can match up the same via piecing: sometimes paying a bit more to avoid headaches is worth it- YMMV.

 

Just ran across this:

The intercooler fits perfectly in size, and you don't need to saw off anything or apply any effort to put the bumper back. Custom made corners, bolts and ABA clamps that you see are included in the kit...quality is very good, u dont have to search for something else.