The car intercooler is one such component that is designed to improve the efficiency of the engine. It is one of the key components used to cool air that has been compressed in a combustion engine. It is often used in turbocharged or supercharged engines. There are two basic types of intercoolers. Air-to-air intercoolers use outside air to transfer engine heat, while air-to-water intercoolers use water to do the same job. Below we have compiled a complete guide on all about intercoolers, their types, advantages and more.
So without further ado, let’s dive into more details about what is an intercooler and how does it work.
What is an Intercooler
The car intercooler is recognised as one of the key components to improve performance in turbo engines. The intercooler is a kind of radiator, or more specifically, a heat exchanger. The turbo intercooler is positioned between the turbo and the intake manifold.
Functions of Intercooler
The purpose of an intercooler is to cool down the air after it has been compressed by the turbo or supercharger before it goes to the car engine.
Intercooler provides better performance, and at the same time reduces fuel consumption. Also, exhaust gas emissions and the thermal load on the engine increase the engine’s reliability when overtaking. Its function is to lower the temperature of the air which rises after the air is compressed by the turbo. The efficiency of an intercooler is measured by the success with which it manages to remove this heat.
When air is heated, it becomes less dense and loses oxygen. In an engine, this can cause several problems. The most common problem is a loss of efficiency. Other problems can include wear and heat damage to the engine block and engine knocking caused by air pockets in the air supplied for combustion.
In an engine, an intercooler compensates for excess heat caused by supercharging or turbocharging an engine. When air is cooled, it becomes denser. This increased density allows more air and fuel to be burned per engine cycle, which ultimately increases engine power output.
Technically, an intercooler is a device used between supercharging or supercharging stages to cool the air for use in the next stage. If the device is used at the end of the boost cycle, it is called an aftercooler. Despite this distinction, the two names are often used interchangeably.
Besides, it also regulates the air temperature and increases the engine’s life and ensures that the air-to-fuel ratio in each cylinder is maintained.
Advantages of Intercooler
The advantages of the intercooler are:
- It cools down the hot compressed air that comes out of the turbo increases its density and manages to deliver a greater mass of air to the engine, thus increasing the engine’s power.
- Reduction of engine temperatures and thermal load allows for an increase in the turbo pressure to higher values. Intercoolers are an important component in all turbocharged engines.
Intercooler efficiency is measured by the ratio between the temperature removed by the intercooler and the temperature increase caused by the turbo. It is measured in percentage.
Front-mounted systems are the most efficient. They sit in the front of the car, where the forward motion of the car can force air through the system. This results in a constant supply of fresh air.
Top-mounted systems are slightly less efficient. They sit on top of the engine, allowing more heat from the engine to affect the intercooler system as the heat increases. Additionally, this configuration does not provide a built-in fresh air source. Many mechanics get around this problem by installing a hood scoop, a raised opening in the hood that allows air to pass into the engine space.
Types of intercooler
There are two types of Intercooler:
Air-to-Air Intercooler
Air to air is one of the most common types of the intercooler. It has better efficiency at higher speeds, greater reliability and less maintenance, as well as lower cost. An air-to-air intercooler works by passing hot air from the engine through tubes. This air is cooled by heat transfer, as cooler air passes outside the tubes. Where the intercooler is mounted on the engine determines the efficiency of the cooling system.
Air-to-Water Intercooler
Air/water types are more efficient at low speeds, causing loss of turbo pressure and better throttle response. An air-to-water intercooler works by transferring heat from the air in the engine to the water. Once the water is heated, it moves away from the hot parts of the engine. It then transfers the heat to the outside air.
Common Causes of Bad Intercooler
- Intercoolers are exposed to external damage and road debris that can cause premature failure.
- Damaged or blocked hoses can cause excessively high pressures that weaken or crack the intercooler.
- Finally, the improper installation of a car turbocharger can cause intercooler blockage and damage.
If the intercooler fails, the engine does not receive enough cold dense air and this prevents complete combustion and consumption of unburned gasoline. Not replacing a faulty intercooler can affect horsepower, gas mileage and emissions.
Common Intercooler Failure Symptoms
- Reduced airflow
- Turbocharger failure
- Engine power drop
- Increase in fuel consumption
- Unusual smoke coming from the exhaust system
That’s the wrap of our guide on all about intercoolers. Now you know the importance of an intercooler in a car, make sure you keep a check on your car maintenance schedule to avoid future breakdowns.
An underperforming intercooler can increase intake air temperatures; however, in the worst case the intercooler can rupture and you can end up with a boost leak. Unfortunately, this will require a new intercooler, as replacing it can be a tedious job.
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