intercoolers

An intercooler, also called a charge air cooler, is a heat exchanger used in turbocharged or supercharged engines to cool the compressed intake air before it enters the engine. Compressing air raises its temperature and reduces density; cooling it increases air density, improves combustion efficiency, and lowers the risk of detonation at high boost.

Most automotive intercoolers are air-to-air units, using ambient air drawn through a core to remove heat from the charge air. Less common are air-to-water (liquid-to-air) designs that transfer heat to a coolant circuit and a separate radiator. Core types include plate-fin and tube-and-fin designs, with aluminum favored for light weight and good thermal conductivity.

Intercooler performance depends on core size, airflow, and heat transfer efficiency. A more effective intercooler allows higher boost and reduces intake temperatures, improving power and reducing engine knock. However, it adds packaging, pressure drop, and potential heat soak after shutdown in some configurations.

Maintenance involves inspecting for leaks, cleaning fins to prevent airflow restriction, and ensuring any coolant circuits are functioning. Inadequate cooling capacity or excessive pressure loss can negate gains, so intercooler selection and tuning should match the engine, boost level, and available space.