An intercooler is a type of heat exchanger used in turbocharged diesel engine truck applications.
Is an Intercooler the same as a Charge Air Cooler?
Yes, in the context of diesel trucks, an intercooler and a charge air cooler (CAC) refer to the same component.
- Intercooler is the general term for any device that cools compressed air before it enters the engine.
- Charge Air Cooler or CAC is the specific term used in diesel engines, especially heavy-duty trucks, to describe the air-to-air intercooler that cools air from the turbocharger before it enters the intake manifold.
So, when people talk about a charge air cooler in a Kenworth, Freightliner, or Peterbilt, they are referring to the intercooler, usually an air-to-air type mounted at the front of the truck.
Air to Air Intercooler
An Air-to-Air Intercooler is a radiator-like device that uses outside air (ambient air) to cool hot compressed air from the turbocharger before it enters the intake manifold.
Air to Air Intercooler is the general term for any device that cools compressed air before it enters an engine. In functional and engineering terms, a Dura-Lite™ Evolution® Charge Air Cooler is an Intercooler. They are built to the highest standards with heavy-duty materials and patented technology to withstand the thermal cycling, vibration, and pressure common in diesel trucks.
What does an Intercooler do?
An Intercooler is used to cool the compressed air coming from the turbocharger on a diesel truck engine before it enters the engine's intake manifold. This cooling process boosts performance, improves fuel efficiency, and helps protect the engine.
Why Is Cooling the Air Important?
Turbochargers compress air to increase engine power. But when air is compressed, it gets hot; hot air is less dense. Less dense air means less oxygen, which limits combustion efficiency. An intercooler cools this air down, making it denser and richer in oxygen. That means better combustion, more power, lower fuel use, and fewer emissions.
Dura-Lite Evolution Intercoolers are widely considered the best in the heavy-duty truck industry due to their superior durability, leak resistance, and long-term performance.
They are purpose-built to solve the most common failures seen in standard OEM and aftermarket Intercoolers.
Intercooler vs. Radiator
Intercoolers and radiators are both heat exchangers found in vehicles, especially diesel trucks but they serve very different purposes. Here's a clear comparison:
Intercooler vs. Radiator: What's the Difference?
| Feature | Intercooler | Radiator |
| Primary Function | Cools compressed air from the turbocharger before it enters the engine. | Cools engine coolant to remove heat from the engine block. |
| Element Being Cooled | Turbo Air (intake/ charge air). | Coolant (liquid). |
| Heat Source | Heat from turbo compression. | Heat from engine combustion. |
| Cooling Medium | Ambient airflow. | Ambient airflow. |
| Type of Heat Exchanger | Air-to-air. | Liquid-to-air. |
| Location | Between turbocharger and intake manifold. | Connected to engine coolant circuit. |
| Used In | Turbocharged heavy duty truck diesel engines. | All internal combustion engines. |
Remember:
- The intercooler cools air for combustion.
- The radiator cools coolant for engine temperature.
Dura-Lite has over 700 different Intercooler and Radiator products available, for same day shipping (when ordered before the cut off time), for purchase online.
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