What if we ran the CO2 discharge line through the intercooler expansion tank before discharging the gas over the heat exchanger? This would enable twice the cooling opertunities and ensure gassing of the CO2 before spraying. We would likely benifit from running the CO2 flow coils inside the expansion tank in the reverse direction of the flow in the tank, bottom to top to maximize heat transfer. Im going to check around for a dry ice can with installed coils that would work as an expansion tank to see what I can come up with.

I think I have the issue of CO2 ingestion figured out but have to wait three weeks until I get back in front of my car to be certain.