What is an intercooler?

An Intercooler, like a radiator is a heat exchanger. An intercooler works much the same as a radiator in engine cooling but instead of liquid, air is cooled after compression.
How does an internal combustion engine benefit from an intercooler?

With Turbocharged or supercharged internal combustion engines, air gets forced into the cylinders. With more air, more fuel can be injected to produce a more powerful and efficient engine. The compressed air does have a downside. Compression of air creates heat which will reduce the efficiency of the turbo or supercharger.

Most modern turbo charged diesel and petrol engines make use of an intercooler also knows as air cooler or charge cooler. In simple terms, the exhaust gasses will spin the turbine of the turbo charger which is linked with a shaft that will spin the compressor wheel of the turbo charger. As the name suggests the compressor wheel will compress air which is forced into the cylinders with certain amount of fuel for the combustion process to take place.

In the process of compressing the air, the air temperature will rise. This is where the intercooler comes into play, the compressed air, which is several degrees higher in temperature, flows through the inside of the intercooler. The ambient air flows through the outside of the intercooler and cools the compressed air inside the intercooler. In South Africa and countries with similar hot climate conditions, the cooler the air flowing into the cylinders the better. Combustion efficiency improves and with that lower fuel consumption and lower exhaust gas temperatures or EGT. Under heavy loads and extremely hot days, the engine will be able to produce more of its maximum power for longer periods of time.
Benefits of a larger more efficient intercooler:

A larger more efficient intercooler will typically reduce air intake temperatures even further. Cooler air is denser. Denser air will improve combustion efficiency which will result in better and longer power delivery and reduced EGTs (Exhaust Gas Temperatures). Lower EGT will ultimately prolong engine life. Lower fuel consumption is also likely. An intercooler upgrade in our hot climate conditions in South Africa is an investment.
Ford Ranger 2.2 110kw
Intercooler Upgrade
600x280x100
R8400 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8500 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 25-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

20-30kw 50-80nm
R3500.00
Ford Ranger 2.2 118kw
Intercooler Upgrade
600x280x100
R8400 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8500 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

15-20kw 30-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

25-40kw 70-120nm
R3500.00
Ford Ranger 3.2 147kw
Intercooler Upgrade
600x280x100
R8400 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8500 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

15-25kw 40-60nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

30-50kw 80-150nm
R3500.00
Ford Ranger 2.0 BiTurbo 157kw
Ford Ranger Raptor 2.0 BiTurbo 157kw
Intercooler Upgrade
600x300x100
R10200 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R9400 Fitted
ECO Tune
Not Available Yet
R999.00
Maximum Performance Tune
Not Available Yet
R3500.00
Isuzu KB250 85kw
(13-On)
Intercooler Upgrade
600x300x76
R7800 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8100 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

8-10kw 20-30nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

10-20kw 40-70nm
R3500.00
Isuzu KB250 100kw
Isuzu D-Max 2.5 TD 100kw
(13-On)
Intercooler Upgrade
600x300x76
R7800 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8100 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 30-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

25-30kw 50-80nm
R3500.00
Isuzu KB300 130kw
Isuzu D-Max 3.0 TD 130kw
(13-On)
Intercooler Upgrade
600x300x76
R7800 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8100 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 40-60nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

25-35kw 70-100nm
R3500.00
Mazda BT-50 2.2 110kw
Intercooler Upgrade
600x280x100
R8400 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8500 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 25-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

20-30kw 50-80nm
R3500.00
Mazda BT-50 3.2 147kw
Intercooler Upgrade
600x280x100
R8400 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8500 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

15-25kw 40-60nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

30-50kw 80-150nm
R3500.00
Mitsubishi Triton 2.5 DiD
Intercooler Upgrade
450x240x65
R7900 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8900 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 25-40nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

20-25kw 50-80nm
R3500.00
Mitsubishi Triton 3.2 DiD
Intercooler Upgrade
450x240x65
R7900 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8900 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 30-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

20-30kw 50-80nm
R3500.00
Mitsubishi Triton 2.4 DiD
Intercooler Upgrade
600x300x76
R8400 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8900 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 30-40nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

20-30kw 50-70nm
R3500.00
Nissan Navara 2.3 140kw
Intercooler Upgrade
600x300x100
R10500 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R11200 Fitted
Incl DPF Delete

ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 30-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

25-30kw 50-100nm
R3500.00
Nissan Navara 2.5 106kw
Intercooler Upgrade
450x300x76
R7900 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8700 Fitted

ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 25-40nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

20-30kw 60-80nm
R3500.00
Nissan Navara 2.5 128kw
Intercooler Upgrade
450x300x76
R7900 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8700 Fitted

ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 25-40nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

15-25kw 40-60nm
R3500.00
Nissan Navara 2.5 140kw
Intercooler Upgrade
450x300x76
R7900 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8700 Fitted

ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 25-35nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

15-20kw 40-50nm
R3500.00
Nissan Navara 3.0 V6 dCi V9X
Intercooler Upgrade
600x260x100
R8600 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8900 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

15-20kw 30-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

20-30kw 70-100nm
R3500.00
Nissan NP300 2.5
Intercooler Upgrade
+50%
R6700 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R7600 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

5-10kw 25-30nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

10-20kw 40-70nm
R3500.00
Toyota Hilux 2.5 D4D 75kw
Intercooler Upgrade
450x300x76 (Front Mount)
R9500 Fitted
Exhaust Upgrade
63mm Stainless Steel

Performance Exhaust System
R8900 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

5-10kw 15-30nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

10-20kw 30-60nm
R3500.00
Toyota Hilux 3.0 D4D 120kw
Intercooler Upgrade
450x300x76 (Front Mount)
R9500 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8900 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 30-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

25-40kw 70-120nm
R3500.00
Toyota Fortuner 3.0 D4D 120kw
Intercooler Upgrade
450x300x76 (Front Mount)
R9500 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R8900 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 30-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

25-40kw 70-120nm
R3500.00
Toyota Hilux 2.4 GD6 110kw
(16-20)
Intercooler Upgrade
600x260x100
R8400 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
Standard R9400 Fitted
Small Box R9400 Fitted
Boxless R8500 Fitted
ECO Tune
ECU Remapping (Auto Only)

Custom Tuned on Dyno

10-15kw 30-40nm
R999.00
Maximum Performance Tune
ECU Remapping (Auto Only)

Custom Tuned on Dyno

20-30kw 60-80nm
R3500.00
Toyota Hilux 2.8 GD6 130kw
(16-20)
Intercooler Upgrade
600x260x100
R8400 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
Standard R9400 Fitted
Small Box R9400 Fitted
Boxless R8500 Fitted
ECO Tune
ECU Remapping (Auto Only)

Custom Tuned on Dyno

10-15kw 30-50nm
R999.00
Maximum Performance Tune
ECU Remapping (Auto Only)

Custom Tuned on Dyno

20-30kw 60-100nm
R3500.00
Toyota Fortuner 2.4 GD6 110kw
(16-20)
Intercooler Upgrade
600x260x100
R8400 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R9400 Fitted
ECO Tune
ECU Remapping (Auto Only)

Custom Tuned on Dyno

10-15kw 30-40nm
R999.00
Maximum Performance Tune
ECU Remapping (Auto Only)

Custom Tuned on Dyno

20-30kw 60-80nm
R3500.00
Toyota Fortuner 2.8 GD6 130kw
(16-20)
Intercooler Upgrade
600x260x100
R8400 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R9400 Fitted
ECO Tune
ECU Remapping (Auto Only)

Custom Tuned on Dyno

10-15kw 30-50nm
R999.00
Maximum Performance Tune
ECU Remapping (Auto Only)

Custom Tuned on Dyno

20-30kw 60-100nm
R3500.00
Toyota Hilux 2.4 GD6 110kw
(21-On)
Intercooler Upgrade
+50%
R10500 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
Standard R9400 Fitted
Small Box R9400 Fitted
Boxless R8500 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 30-40nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

15-25kw 50-70nm
R3500.00
Toyota Hilux 2.8 GD6 150kw
(21-On)
Intercooler Upgrade
+50%
R10500 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
Standard R9400 Fitted
Small Box R9400 Fitted
Boxless R8500 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 30-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

20-30kw 60-100nm
R3500.00
Toyota Fortuner 2.4 GD6 110kw
(21-On)
Intercooler Upgrade
+50%
R10500 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R9400 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 30-40nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

15-25kw 50-70nm
R3500.00
Toyota Fortuner 2.8 GD6 150kw
(21-On)
Intercooler Upgrade
+50%
R10500 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R9400 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 30-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

20-30kw 60-100nm
R3500.00
Toyota Land Cruiser 79 4.5 V8 D4D
Intercooler Upgrade
Front Mount
R12500 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
Standard R11500 Fitted
Small Box R11500 Fitted
Boxless R10300 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 40-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

25-35kw 70-120nm
R3500.00
VW Amarok 2.0 TDI 90kw
Intercooler Upgrade
+100%
R11500 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R9400 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 30-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

25-35kw 50-80nm
R3500.00
VW Amarok 2.0 TDI 103kw
Intercooler Upgrade
+100%
R11500 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R9400 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 30-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

20-30kw 50-80nm
R3500.00
VW Amarok 2.0 TDI 120kw
Intercooler Upgrade
+100%
R11500 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R9400 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 30-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

20-30kw 50-80nm
R3500.00
VW Amarok 2.0 TDI 132kw
Intercooler Upgrade
+100%
R11500 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R9400 Fitted
ECO Tune
ECU Remapping

Custom Tuned on Dyno

10-15kw 30-40nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

15-25kw 50-80nm
R3500.00
VW Amarok 3.0 V6 TDI 165kw
Intercooler Upgrade
+100%
R11500 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R13900 Fitted
Incl DPF Delete
ECO Tune
ECU Remapping

Custom Tuned on Dyno

15-20kw 30-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

25-30kw 70-100nm
R3500.00
VW Amarok 3.0 V6 TDI 190kw
Intercooler Upgrade
+100%
R11500 Fitted
Exhaust Upgrade
76mm Stainless Steel

Performance Exhaust System
R13900 Fitted
Incl DPF Delete
ECO Tune
ECU Remapping

Custom Tuned on Dyno

15-20kw 30-50nm
R999.00
Maximum Performance Tune
ECU Remapping

Custom Tuned on Dyno

25-30kw 70-100nm
R3500.00
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