Intercooler

Intercoolers are heat exchangers positioned between a turbocharger or supercharger and the intake manifold. Their primary function is to reduce the temperature of the compressed air, increasing its density and improving engine volumetric efficiency. Construction typically utilizes a core with fin and tube or bar and plate designs, fabricated from aluminum alloys for thermal conductivity and weight reduction. Intercoolers employ both air-to-air and air-to-liquid (water-cooled) designs, each with varying pressure drop and cooling capacity characteristics. Performance is rated by pressure drop, fin density, and thermal efficiency, influencing boost pressure and engine output. End tanks are typically cast aluminum or plastic and are designed for specific hose and mounting configurations.