The intercooler, or charge air cooler, cools the hot compressed air from the turbo before it enters the engine, and a leak here quietly robs power and economy.
What it does
After the turbo compresses intake air, that air is hot and less dense. The intercooler cools it so the engine gets a denser charge, which improves power, efficiency, and combustion. Cracks, leaks, or oil buildup reduce that benefit.
Signs it is failing
- Loss of power and boost
- Reduced fuel economy
- Boost-leak codes or underboost
- Oil residue at the couplers
Replacement and what to know
A cracked intercooler or failed couplers and clamps are replaced, and the charge-air plumbing is inspected for leaks. On trucks that tow or run higher boost, a quality intercooler and tight connections keep intake temperatures and power where they should be.
Frequently asked questions
What does an intercooler do?
It cools the hot compressed air from the turbo so the engine gets a denser, cooler charge for better power and efficiency.
What are signs of an intercooler leak?
Loss of power and boost, reduced economy, boost-leak or underboost codes, and oil residue at the couplers.
Can a boot or clamp cause the problem?
Yes. Failed couplers and clamps are common leak points and are cheaper to address than the intercooler itself.
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