Intercooler

An intercooler is a heat exchanger used in forced induction engines to cool the air compressed by a turbocharger or supercharger before it enters the engine. By lowering the temperature of the charge air, an intercooler increases air density, allowing more oxygen for combustion and reducing the likelihood of detonation and engine knock. This can improve power output, efficiency, and engine reliability by reducing thermal stress on the intake charge.

Most intercoolers are air-to-air heat exchangers that use ambient air to reject heat. They are typically positioned in the vehicle's front end or behind the bumper to maximize airflow. In applications with limited cooling airflow, air-to-water intercoolers use a liquid coolant circuit and a radiator to reject heat, enabling more compact or higher-boost installations.

Core design varies; common types include plate-and-fin and tube-and-fin architectures, with aluminum as the typical material due to light weight and good thermal conductivity. Intercoolers introduce some pressure drop in the charge air path, so their size and core density are balanced against expected airflow and boost.

Intercoolers are standard on many turbocharged and supercharged engines, including cars, trucks, and performance motorcycles, and are also used in some aircraft and industrial turbo systems. Maintenance considerations include checking for oil contamination, cleaning the core, and ensuring hoses and clamps remain secure.