{"id":5057,"date":"2020-11-27T22:11:05","date_gmt":"2020-11-27T22:11:05","guid":{"rendered":"https:\/\/www.xtremediesel.com\/blog\/?p=5057"},"modified":"2022-09-09T02:40:47","modified_gmt":"2022-09-09T02:40:47","slug":"intercooler-101-what-does-an-intercooler-do","status":"publish","type":"post","link":"https:\/\/www.xtremediesel.com\/blog\/2020\/11\/27\/intercooler-101-what-does-an-intercooler-do\/","title":{"rendered":"Intercoolers 101 – What does an Intercooler do?"},"content":{"rendered":"\n
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One negative side effect of a turbocharger is that when you compress air, it heats up. The temperature of the discharged air from a turbo can exceed 500\u00b0F (at higher boost levels). Rising temperatures also result in a drop in air density. One popular way of combatting this is with the use of an intercooler<\/a>.<\/p>\n\n\n\n

Air-To-Air Heat Exchanger<\/h3>\n\n\n\n

Intercoolers (which can also be referred to as an aftercooler or charge-air cooler) are standard equipment on most late-model turbocharged vehicles nowadays. The hot air discharged from the turbo is routed through a stack of tubes with internal fins. Heat is transferred from the pressurized air to the fins and then to the outside of the metal tubes. As outside ambient air flows over the intercooler the heat is transferred out of the tubes through external fins. The result is cooler air delivered to the engine. The intercooler used in this process is commonly referred to as an air-to-air heat exchanger. This setup is found in most diesel applications.<\/p>\n\n\n\n

Water-To-Air Heat Exchanger<\/h3>\n\n\n\n

Some setups such as the 2011+ Ford 6.7L Powerstroke use water (or coolant) rather than air to cool the air discharged by the turbocharger. A pump circulates coolant thru the closed system from the radiator to the heat exchanger. While the coolant and air don\u2019t actually make contact, the heat transfer is extremely efficient. There are a few other benefits to using a water-to-air setup. The intercooler cores are generally much smaller and less piping is required, which offers reduced turbo lag and getting the turbo to peak boost faster. <\/p>\n\n\n\n

A setup like this is generally reserved for heavy-duty or race applications. These are also found on many performance vehicles from the factory. It does require additional accessories compared to air-to-air setups, advancing its complexity and the associated costs. This can also increase the possibility of a leak if not done properly.<\/p>\n\n\n\n

The Benefits of Cold Air<\/h2>\n\n\n\n

As you may remember from science class, cold air is denser than warm air. Cold air features molecules that are packed together closer. When air is heated, the molecules start to move around faster. They become spaced further apart, so there is less oxygen. The number of oxygen molecules entering the combustion chamber per unit volume of air can be significantly greater with colder air. Cold air also helps to produce lower exhaust gas temperatures (EGT) when the same amount of fuel is delivered. It can also provide an increase in power levels at the same EGT, because of the ability to add more fuel.<\/p>\n\n\n\n

Symptoms of Intercooler Failure<\/strong><\/h2>\n\n\n\n