Intercoolers

Intercooler – charge air cooler

Arcoore offers intercoolers for all brands of trucks, commercial vehicles, agricultural and construction machinery. We offer both new and reconditioned intercoolers that meet the highest quality standards.

Every product is covered by a twelve-month warranty, which gives our customers confidence in its reliability and durability. Before shipment, each part is carefully protected against mechanical damage and undergoes a detailed technical and quality inspection.

What is an intercooler?

The intercooler, also known as the charge air cooler, is a key component of the intake system in supercharged engines. Its main task is to lower the temperature of the air compressed by the turbocharger or compressor before it enters the engine cylinders. Cooler air has a higher density, which means that it contains more oxygen per unit of volume. This, in turn, translates into better combustion of the air-fuel mixture and increased engine power.

Nowadays, the use of intercoolers is standard in supercharged engines, regardless of whether they are mechanically supercharged or turbocharged. Air coolers for trucks, as well as for passenger cars and special machinery, are an essential part of the intake system, affecting performance and fuel economy.

How do intercoolers work?

Intercoolers work on the principle of heat exchange, just like liquid coolers. The air compressed by the turbocharger or compressor is very hot, which reduces its density and combustion efficiency. It enters thick pipes that lead to the intercooler, where the air is cooled by atmospheric air. Therefore, air coolers for trucks and other vehicles are usually installed at the front, near the bumper, to ensure maximum cooling air flow.

Unlike liquid coolers, intercoolers do not have fans to assist cooling. The whole process happens naturally through the air flow while driving. The cooler air goes from the intercooler to the cylinders, which results in more efficient fuel combustion.

Why use an intercooler?

The main purpose of an intercooler is to improve engine performance. Cooled air is denser, which means that it contains more oxygen needed for combustion. This directly translates into an increase in engine power. Reducing the air temperature by just 10 degrees Celsius can increase its density by 3-5%, which results in a similar increase in power.

Standard intercoolers can reduce the temperature of the charge air by up to 40%. This not only improves performance, but also reduces the risk of knocking and engine wear. Thanks to the intercooler, the engine works more efficiently and economically.

The impact of the intercooler on exhaust emissions and ecology

Modern combustion engines must meet increasingly stringent exhaust emission standards, such as Euro 6. One of the elements that has a significant impact on emission reduction is the intercooler. By cooling the charge air, the process of fuel combustion is improved, which results in lower emissions of nitrogen oxides (NOx) and particulate matter.

An efficient intercooler also helps to reduce fuel consumption, which directly reduces the vehicle’s carbon footprint. It is worth remembering that a damaged or dirty intercooler can cause the engine to malfunction, leading to higher exhaust emissions and higher fuel consumption.

What are the most common causes of intercooler failure?

Intercoolers are exposed to mechanical damage because they are not protected, which could limit airflow. The most common causes of failure include:

• Mechanical damage – stones and other small objects can hit the intercooler, causing cracks or dents, which leads to intake system leaks,
• Contamination – accumulated dust, oil or soot can settle in the intercooler, reducing its ability to cool the air and decreasing engine performance.
• Problems with the turbocharger – oil leaks from a damaged turbocharger can enter the intercooler, leading to contamination and reduced air cooling efficiency.
• Corrosion and material wear – long-term use and weather conditions can cause gradual wear and tear of the intercooler, which increases the risk of damage.

Symptoms of a damaged intercooler – what to look out for?

When the intercooler is damaged, it can cause a number of problems with the engine, which negatively affect driving comfort and fuel economy. The most common symptoms include:

• decrease in engine power – a damaged intercooler causes an increase in the temperature of the charged air, which results in worse combustion and lower engine power,
• Stuttering while driving – a leaky intercooler or a dirty system can cause disruptions in the air supply to the engine, which manifests itself in the form of uneven operation of the power unit and stuttering while accelerating or shifting gears.
• difficulty accelerating – when the intercooler is not working properly, warmer air enters the engine, which reduces its efficiency. As a result, the car reacts more slowly to the addition of gas,
• increased fuel consumption – an engine that does not receive enough cool air works less efficiently, which leads to increased combustion,
• uneven engine operation – a leaky or dirty intercooler can cause unstable engine speeds, especially when idling.

If you notice any of the above symptoms, it is worth checking the condition of the intercooler as soon as possible. Early diagnosis and possible repair can prevent more serious engine problems and costly repairs. In case of damage, it is worth checking whether the problem is due to leaks, dirt or mechanical damage such as cracks or oil leaks.

How do I check if the intercooler is working properly?

The basic step in assessing the efficiency of the intercooler is a visual inspection – both of the cooler itself and of the air ducts leading to and from it.

Check for visible mechanical damage such as cracks, dents or leaks. Rubber and metal air supply and exhaust hoses can wear out or become leaky, and visible cracks or abrasions can indicate problems.

If the visual inspection does not reveal any irregularities, you can carry out a pressure test or disassemble the intercooler and look for traces of oil, which may indicate problems with the turbocharger.

If irregularities are detected, it is advisable to take corrective action as soon as possible to ensure that the engine and turbocharging system work properly. If you have any doubts as to whether the intercooler in your vehicle is working properly, consult a specialist or consider having it reconditioned or replaced with a new model.

New and reconditioned intercoolers from Arcoore

We offer new and remanufactured intercoolers for all truck brands, such as man, DAF, Scania, Volvo, Renault, Iveco, Mercedes. We also offer intercooler reconditioning services for:

• Buses: Mercedes, man, Scania, Volvo, Solaris, VDL, Van Hool, Setra, Neoplan, Autosan, Bova, Irisbus, Iveco, Irizar, Renault, Solbus, SOR, DAF, Karosa
• Agricultural machinery: Case, Claas, John Deere, Deutz, Fiat, Hanomag, Kubota, Landini, Massey Ferguson, New Holland, Renault, Steyr, Ursus, Zetor
• Construction machinery: Bobcat, Caterpillar, Cat, John Deere, Fuchs, Hanomag, Komatsu, Kubota, Liebherr, Manitou
• Locomotives: PESA, NEWAG, Stadler, Skoda, SM series, ST series, MTU, Voith
• Industrial machinery and wind turbines.

We offer a 12-month warranty on all our products. Each intercooler undergoes a thorough quality and technical inspection before shipping, which guarantees the reliability and durability of our products.

Contact us today!

If you did not find the intercooler you are looking for in our shop, need an individual offer, want to refurbish an existing cooler or require further information, please contact us. Whether you need a new or a refurbished intercooler – we will find the perfect solution for you!