Intercoolers

Is your charge air getting hot, so the engine can lose power on repeated pulls? An intercooler cools the air after the turbo or supercharger, giving the engine denser air. Here you'll find intercoolers for street cars, track cars and heavy-duty diesel vehicles, both as complete kits and individual parts.

What does an intercooler do?

When the turbo increases boost pressure, the air gets hotter. An intercooler lowers the temperature before the air reaches the engine. This typically gives more consistent power and can reduce the risk of knock. An air-to-air intercooler sits at the front of the car and is cooled by the airflow while driving. A water-to-air intercooler uses coolant and a separate heat exchanger, so it can be placed closer to the engine with shorter piping.

How to choose an intercooler

• Cooling capacity: depends on, among other things, the core design, surface area and airflow.
• Pressure drop: a dense core can cool effectively, but can also cost boost pressure.
• Space: check the clearance to the radiator, bumper and sensors.
• Power goals: the more power your project is aiming for, the more cooling capacity you will typically need.

Size alone doesn't determine performance, and a very large core can give slightly slower response. You'll find, for example, OEM-style intercoolers from CSF for Ram and Ford, as well as intercoolers from Wagner Tuning, do88, Mishimoto and Garrett.

Installation and maintenance

Many models are vehicle-specific, such as the COBB kit for the Honda Civic Type R. You will often also need new charge pipes or parts from intercooler accessories. If you want the piping and brackets included, an intercooler kit may be the right choice. Regularly check hose clamps and joints for leaks, and clean dirt and insects off the front of the core.

Frequently asked questions

Should I choose air-to-air or water-to-air?

Air-to-air is simple and requires no pump, but needs space at the front and longer piping. Water-to-air gives short piping and quick response, but requires a pump, heat exchanger and coolant circuit. The choice depends on the car, available space and intended use.

Does a new intercooler need to be approved for road use?

It depends on the product, the car and the extent of the modifications. Check what applies to the specific part number, and confirm with a vehicle inspection centre whether the modification needs approval before you install it.

Why can my car lose power after installation?

Typical causes are a leaking joint, a loose hose clamp or incorrectly fitted sensors, which can lead to lower boost pressure or fault codes. Some cars also require adjusted engine software to take full advantage of the new intercooler.