What is a diesel intercooler: types of device, principle of operation and installation on a car

2024 Author: Erin Ralphs | [email protected]. Last modified: 2024-02-19 11:42

Every year there are more and more diesel cars. And if a few years ago diesel engines were only found on commercial vehicles, now passenger cars with tractor engines are by no means a rarity. There are reasons for this, and quite objective ones. Such cars consume half as much fuel with the same performance. But you need to understand that the design of diesel engines is somewhat different. Since almost all of them come with a turbine (otherwise it will not be possible to significantly increase the performance of the internal combustion engine), there will also be an intercooler on a diesel engine. What is an intercooler, what is it for? Read the answers to these and many other questions further in our article.

Characteristic

So, what is an intercooler in a diesel car? This is an intermediate radiator, which is located in the air supply system to the internal combustion engine cylinders. What is a diesel intercooler for? The main task of thiselement is to cool the air. It should be noted that this radiator is installed not only on diesel cars. You can also meet them on gasoline cars, but this only applies to sports specimens that are equipped with a powerful turbine. And the installation of an intercooler on a diesel is often done at the factory. Yes, these radiators are somewhat smaller than those on cars with gasoline turbo engines, but the compressor itself is less efficient.

Working principle

We know what an intercooler is in a diesel car. But how is it possible to use it to make the air colder? This task is achieved very simply. The principle of operation is the same as that of a conventional radiator of the cooling system. Due to the large area of contact with the environment, the air is quickly cooled like antifreeze in the SOD. No additional elements are needed for this. Air passes through the interior of the intercooler on its own. The scheme is simple, cheap and practical. With such a device, you should not be afraid of any breakdowns. The only thing you need to keep the radiator clean (more on that later).

Why is this element not found on atmospheric internal combustion engines? In such engines, oxygen is supplied by vacuum in the intake system (it is created when the piston moves down). On turbocharged ones, air is forcibly forced by the compressor impeller. Since there is more oxygen, and the volume of the intake system is small (no more than on atmospheric internal combustion engines), it startsshrink. We know from the laws of physics that when air is compressed, it heats up. Why is it harmful? Hot air is the enemy of the internal combustion engine. It affects the performance of the motor, detonation can also occur. The colder the air, the better. Therefore, the intercooler is installed on turbocharged cars (often it is installed behind the filter in front of the manifold).

Device

Outwardly, this element is similar to a conventional radiator. It also has many plates and moves. The device also has cooling pipes. They are made as long as possible. It is also important that the tubes are straight, otherwise they may kink, resulting in loss of pressure. In addition to the nozzles, plates are welded. This is necessary for more efficient heat transfer. Usually aluminum or copper is chosen as the material for the radiator. These metals have the highest thermal conductivity. This element is installed, as we have already said, between the intake manifold and the turbocharger. Usually it is hidden under the front bumper. Sometimes placed near the main cooling radiator.

Types

There are several types of intercoolers:

• Air. This is the most popular type. In this case, cooling is carried out by the oncoming air flow, which is formed when the car is moving at speed.
• Liquid. In this situation, the liquid contributes to the cooling. The advantage of the system is that the radiator is more compact. Also, liquid absorbs heat better than air. But in the device, the fluid system is more complex. Therefore, it is installed much less frequently.

Does this work?

How efficient is an intercooler in a turbocharged car? As practice shows, this element is very important and effective. Cooling the air by 20 degrees gives a six percent increase in power. And since the intercooler is able to cool the air immediately by 50-60 degrees, this increases the performance of the motor by more than 15%. If we talk about liquid systems, they are able to cool the air by 70-80 degrees. And this is almost a quarter of the total power of the internal combustion engine. Therefore, it is not in vain that an intercooler is installed on the Kia Sorento diesel engine, as well as on other turbocharged cars. It really brings positive results.

System flaws

Considering what a diesel intercooler is, it is worth noting its disadvantages:

• Lower pressure. In any case, the air should not pass directly, but through certain highways and labyrinths. Therefore, part of the energy that the turbine gives is lost.
• Mass. Some radiators can weigh up to 15 kilograms.
• The need for additional coolant (applies to the second type of intercoolers). In addition, you need to monitor the tightness of the system and always control the level. If there is no liquid in the system, the efficiency of the intercooler is reduced significantly.

Is it possible to close the intercooler in winter on a diesel?

Some owners wonder ifwhether it is possible to close this element and whether it will bring the result. I must say that cold air (even negative temperatures) is not harmful to the engine. But condensate is harmful, which can accumulate due to temperature differences. What do experts say about this issue?

It makes sense to close the radiator when the ambient temperature is below -25 degrees. If the car is used in the city or in deep snow, it is better to leave the radiator open. The motor strains more than when driving on the highway, so the air must be cooled down. In combined mode (city-highway), it is better to close the radiator half way.

As for highway driving, it is better to close the intercooler here (if the air temperature is below -25). But nothing terrible will happen, experts say, if this recommendation is ignored.

Can it be removed?

Some car owners are thinking about removing this design, based on one of the drawbacks (air passes more slowly, which reduces the efficiency of the turbine). But experts do not advise taking such measures. Increasing power in this way will not work. Moreover, due to hot air, on the contrary, it will drop significantly. In addition, the engine and intake system are not designed for such high temperatures. Therefore, dismantling the intercooler can only do harm.

How to increase power?

You can't remove the intercooler. But what if you want to increase engine performance? A reasonable solution is to install a larger radiator. Thus the air willpass faster and at the same time cool no less qualitatively. The next step is to install the air intake on the hood. Subaru owners often implement this idea.

About operation

It is important not only to know what a diesel intercooler is, but also to properly maintain it. The main enemy is dirt. It interferes with normal heat transfer. As a result, there is hot air in the intake and a drop in power. It is necessary to clean the element not only outside, but also inside. How to check the intercooler on a diesel for contamination? Alas, it will be possible to do this only after its dismantling. Having removed the nozzles, we will see if there is oil inside. If the turbine drives oil, it will certainly end up in the intercooler. Then you need to take a carburetor cleaner and thoroughly wash the greasy traces. A clean intercooler is the key to the stable operation of a turbocharged engine.

Conclusion

So, we have looked at what a diesel intercooler is. As you can see, this is a very important element in cars with turbocharged engines. It cannot be removed and it is important to control its cleanliness. Only in this way will the system be effective.