The way I keep asking for more sensors, my builder is going to hate me. Maybe the best approach is to go for as large a cooler you can reasonably fit and look at the IATs.
Seems to be a real old school guy with an never change a running system attitude 😅. Anyway, for the speed density approach you need:
- fuel mass system parameters: MAP, MAT, engine speed, fuel pressure
- fuel mass system correction and safety: ECT, PA, EGT, lambda
This is the bare minimum of to be measured parameters to run a boosted engine correctly. If you turbo charger is already limited for your application a shaft speed sensor on the turbo is duty too. Doesn't matter if choke, surge or speed line limits, if any of these are possible to be touched, then add a speed sensor at the turbo and model the compressor map to setup a protection module for that functionality.
Regarding the efficiency map of the heat exchanger, you need to know the mass flows on both sides to utilize that information rational, thence to model the engine combustion and alternation of load as well as the coolant pressure system is duty for that. Beside myself, I don't know anyone who has done the effort 😎. What I would recommend is not the biggest possible, I would recommend one who has the best inflow design, which is smaller and therefore longer to supply the necessary area. The design above in the CRV enginebay is very challenging at the inlet. It is very likely that only 45 % of the supplyied front face area is used at full flow, the inhomogeneity of that design is system immanently.