Charge Air Cooler (Intercooler) System

The charge air cooler systems' function is to reduce the temperature of the air charge that is heated during the turbocharging process to improve the efficiency and performance of the engine. The intercooler uses conventional coolant that is separate from the engine cooling system. The intercooler system includes a cover, two heat exchangers, water manifold, charge air cooler radiators, and an electric coolant pump. The coolant pump transfers coolant from the radiator to the water manifold which then directs coolant to the heat exchangers via transfer tubes. Coolant enters the inlet port of the water manifold assembly, is directed into and through the charge air coolers/heat exchangers, and exits back into the water manifold. Coolant then exits the water manifold outlet port returning to the separate cooling system radiators. The charge air coolers can reduce the compressor outlet air temperature by up to 74°C (133°F), which enhances performance. This is due to the higher density of oxygen in the cooled air, which promotes optimal combustion. The charge air cooler inlet air tubes are connected to the turbochargers by flexible rubber hoses that require the use of special high torque fastening clamps. In order to prevent any type of air leak when servicing the hoses and tubes, the tightening specifications, cleanliness and proper positioning of the clamps is critical, and must be strictly adhered to.