Intercooler: replacement and selection

When and why an intercooler needs replacement

Lifetime limit of an intercooler is not specified by manufacturers. The component is replaced in case of housing integrity violation or damaging the pipe gaskets.

Defects can be related to excessive pressure inside the part, caused by malfunction of a bypass valve. Moreover, destruction of a protective film on the metal surface under the influence of thawing salts leads to breakdown of the intercooler, as well as ingress of oil into the part due to wear of turbocharger bushes or operation of the engine at high rpm. Improper operation of the intercooler leads to delayed turbocharger turning on, lowering of engine torque and abrupt increasing of fuel consumption.

The component is installed together with a set of pipes, which are usually included in a kit. Note that air-to-liquid intercoolers require frequent replacement of antifreeze: old coolant withdraws heat worse, which speeds up the intercooler wear-out.

How to select an intercooler

The main characteristic, by which components significantly differ is the cooling method: air-to-air or air-to-liquid. Air-to-air intercoolers are efficient when vehicle moves at high speeds. Advantages of this type of components are simple design and more affordable maintenance. Disadvantage is a bigger size, which makes installation difficult. A component with water cooling, which uses antifreeze, is efficient even at small speeds, but is more complex and expensive at servicing.

In order to make intercooler perform its functions properly, it is advisable to install a component from a well-recommended manufacturer. Vemo, Dasis, Denso, NFR, Van Wezel and others are amongst such manufacturers.

It is important to take into account installation location of the component when selecting an intercooler. Some intercoolers are designed to be front mounted before the radiator or inside of one of the front car fenders. There are also parts which are top mounted above the engine.

Also consider thickness of the intercooler, frontal area, diameter of an intake channel, thickness of walls. Moreover, plate layout density is relevant. Dense structure of the part leads to excessive air friction, thus lowering the pressure and cooling performance as well.