Different types of intercooler There are two main types of intercooler, which work in different ways: Air-to-Air The first variant is the air-to-air intercooler, which works by passing the compressed air through a network of small tubes, past a series of cooling fins. Air-to-water As the name suggests, air-to-water intercoolers use water to lower the temperature of the compressed air. Placement of intercoolers Whilst in theory, air-to-air intercoolers can be located anywhere between the turbo and the engine, they are most effective where there is better airflow, and are usually placed at front of the vehicle, behind the grille.
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Tick this box to be informed of future special offers by email. This means that the placement of the intercooler itself is vital and can cause many headaches in terms of routing the necessary plumbing. To produce some form of safety factor, air-to-air intercoolers are often relatively large in size to maximise the surface area for cooling.
These systems are slightly more complicated but follow the same main ideas. The thermal conductivity of water is much higher than that of air which means heat is transferred much more efficiently. The only placement dilemma comes in the form of the water-cooling heat exchanger that needs cold airflow to function efficiently.
Unfortunately, this also means that this type of intercooler needs a water pump, a fluid reservoir and the relevant piping for the water to navigate its way around the system. Most intercoolers need to be placed in an area where air flow is fast, smooth and cool. This is why front-mounted intercoolers are the most popular method of placement. Either positioned in front of the radiator or within a side grill of the front-end, an intercooler should always receive cold and undisturbed air to maximise the temperature difference between the hot and cold fluids.
If space is at a premium, manufacturers will often create large air scoops in the bonnet Subaru Impreza WRX STI, Mini Cooper S so that the intercooler can be placed anywhere in the engine bay and still have a sufficient air supply.
Although they can be a massive hassle to implement into a engine and powertrain system, intercoolers hold the key to effective forced induction through their air cooling capabilities.
An intercooler engineered to the correct size could unlock precious power from an engine and with almost every car manufacturer downsizing and turbocharging, expect to see many of the heat exchangers under the bonnets of your future cars. They may almost seem like a vulgar fashion accessory in the modified car scene, but function very much transcends form in this instance.
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