Car Modding, Motorsport, Formula 1

Intercoolers that exchange their heat directly with the atmosphere are designed to be mounted in areas of an automobile with maximum air flow. These types are mainly mounted in front mounted systems (FMIC). Cars such as the Nissan Skyline, Saab, Volvo 200 Series Turbo, Volvo 700 Series (and 900 series) turbo, Dodge SRT-4, 1st gen Mazda MX-6, Mitsubishi Lancer Evolution and Chevrolet Cobalt SS all use front mounted intercooler(s) mounted near the front bumper, in line with the car’s radiator.

Many older turbo-charged cars, such as the Toyota Supra (JZA80 only), Nissan 300ZX Twin Turbo, Nissan 200SX (S13/14/14a/15), Mitsubishi 3000gt, Saab 900, Volkswagen, Audi TT, and Turbo Mitsubishi Eclipse use side-mounted air-to-air intercoolers (SMIC), which are mounted in the front corner of the bumper or in front of one of the wheels. Side-mounted intercoolers are generally smaller, mainly due to space constraints, and sometimes two are used to gain the performance of a larger, single intercooler. Cars such as the Subaru Impreza WRX, MINI Cooper S, Toyota Celica GT-Four, Nissan Pulsar GTI-R, Mazdaspeed3, Mazdaspeed6, [] and the PSA Peugeot Citroën turbo diesels, use air-to-air top mounted intercoolers (TMIC) located on top of the engine. Air is directed through the intercooler through the use of a hood scoop. In the case of the PSA cars the air intake is the grille above the front bumper, then flows through under-hood ducting. Top mounted intercoolers sometimes suffer from heat diffusion due to proximity with the engine, warming them and reducing their overall efficiency. Some World Rally Championship cars use a reverse-induction system design whereby air is forced through ducts in the front bumper to a horizontally-mounted intercooler.

Turbochargers and superchargers are engineered to force more air mass into an engine’s intake manifold and combustion chamber. Intercooling is a method used to compensate for heating caused by supercharging, a natural byproduct of the semi-adiabatic compression process. Increased air pressure can result in an excessively hot intake charge, significantly reducing the performance gains of supercharging due to decreased density. Increased intake charge temperature can also increase the cylinder combustion temperature, causing detonation, excessive wear, or heat damage to an engine block.

Passing a compressed and heated intake charge through an intercooler reduces its temperature (due to heat rejection) and pressure (due to flow restriction of fins). If properly engineered, the net result is an increase in density. This increases system performance by recovering some losses of the inefficient compression process by rejecting heat to the atmosphere. Additional cooling can be provided by externally spraying a fine mist onto the intercooler surface, or even into the intake air itself, to further reduce intake charge temperature through evaporative cooling.