A Charge Air Cooler (CAC) is a heat exchanger that reduces the temperature of compressed air before it enters the engine's intake manifold. It is used for turbocharged engines to improve efficiency and performance.
Scientific Working Principle of a Charge Air Cooler
Compression and Heating of Air:
A turbocharger compresses intake air, increasing its pressure. Due to compression, the air temperature rises. Hot air is less dense, which reduces the oxygen content entering the engine.
Heat Transfer in the Charge Air Cooler:
The hot compressed air passes through the charge air cooler. The cooler works like a radiator using air to remove heat. Heat is transferred from the hot compressed air to the cooling medium via conduction and convection.
Cooling and Increasing Air Density:
As heat is removed, the air cools down and becomes denser. Cooler denser air contains more oxygen per unit volume leading to better combustion. This increases power output.
Heat Transfer Mechanisms:
Conduction: Heat moves from the hot air to the cooler metal surfaces of the heat exchanger.
Convection: The cooling medium (air) absorbs heat and carries it away.
Radiation (minor effect): Heat is also radiated away from the cooler's surface.
Charge Air Cooler Tester
The Dura-Lite™ Charge Air Cooler Tester-Kit™ is a tool designed to leak test charge air coolers (CACs) used in turbocharged diesel engines. It helps to detect leaks and pressure losses, which can significantly impact engine efficiency, power output, and fuel economy.
How the Dura-Lite Charge Air Cooler Tester Works:
Sealing the Charge Air Cooler
The Tester-Kit includes expandable rubber seals (also called plugs) that are inserted into the charge air cooler inlet and outlet ports.
These seals prevent air from escaping except through leaks.
Pressurizing the System
Compressed air is introduced into the CAC using a regulated air supply (usually from a shop compressor).
The system is gradually pressurized to a set level (typically 35 psig for most applications).
Leak Detection
The pressure is monitored using a built-in gauge.
If the pressure drops over time, it indicates a leak.
Assessing Performance
A properly functioning charge air cooler should maintain pressure for at least 15 seconds without significant loss.
Any pressure drop beyond the allowable limit indicates a need for repair or replacement.
Video on how to use Dura-Lite’s Charge Air Cooler Tester-Kit
Buy a Dura-Lite Charge Air Cooler Test Kit:
Dura-Lite Evolution Charge Air Cooler
Leak-Proof and Durable Construction
Evolution® Charge Air Coolers use Dura-Lite’s Patented high temperature silicone grommet tube-to-header seal system instead of traditional brazed joints, which are prone to cracking.
Prevents heat stress fractures that lead to boost leaks and performance loss.
High Thermal Efficiency
Cools compressed air more effectively, increasing air density and optimizing combustion.
Helps maintain engine power output and fuel efficiency by reducing turbo workload.
Lightweight Yet Strong Design
Made from aluminum for a balance of strength and weight savings.
Resistant to corrosion and heat cycling, ensuring longevity.
Tested for Leak-Free Performance
Manufactured leak-free, each Evolution charge air cooler is tested underwater to ensure it is leak-free before leaving the factory.
Dura-Lite’s Evolution® charge air cooler has a 7 Year/ 1,000,000 Mile Warranty.
Warranty Labor is covered for the first 2 (two) years from the Installation Date.
Compatible with OEM and Aftermarket Systems
Charge Cooler
A Charge Cooler and a Charge Air Cooler (CAC) serve similar purposes but are not exactly the same. Both are used in turbocharged engines to cool compressed intake air before it enters the engine. However, the key difference is in how they transfer heat.
Charge Air Cooler (CAC): Air-to-Air Cooling
Uses ambient air to cool the compressed intake air.
Works like a radiator: Hot charge air flows through a network of tubes while outside air passes over them, dissipating heat.
Commonly found in trucks, diesel engines, and high-performance vehicles due to its simplicity, reliability, and efficiency.
Charge Cooler: Air-to-Liquid Cooling
Uses coolant (water or a water-glycol mix) instead of ambient air to remove heat.
Functions like a small radiator with a heat exchanger, where coolant absorbs heat from the charge air and is later cooled by a secondary radiator.
Often used in high-performance sports cars, marine engines, and industrial applications where space is limited or where air-to-air cooling is less effective.
Sometimes referred to as a Water-to-Air Intercooler.
Which One is Better?
Air-to-Air Charge Air Coolers (CACs): More durable, lower maintenance, and work well for continuous, high-load applications like trucks and diesel engines.
Charge Coolers (Air-to-Liquid Intercoolers): More compact, better for high-performance applications, and provide faster cooling, but require a coolant system and pump.
Buy a Dura-Lite Charge Air Coolers in the USA
Buy Dura-Lite Charge Air Coolers in Canada
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