Intercoolers for Enhanced Performance & Efficiency

Intercoolers for Enhanced Performance & Efficiency

An intercooler is the single most important component in a turbocharged induction system for supporting power gains from higher boost. By cooling compressed air before it enters the engine, an upgraded intercooler delivers denser, cooler charge air that allows more fuel to be safely injected and combusted, directly translating to more horsepower and torque.

Popular Upgrades

Best-selling intercooler upgrades include front-mount bar-and-plate aluminum intercoolers for Subaru WRX and STI, Mitsubishi Evo, and Volkswagen GTI platforms, direct-fit top-mount intercooler upgrades for rotary and compact turbo applications, and heavy-duty intercooler upgrades for Ford Powerstroke and Dodge Cummins diesel trucks where factory coolers are prone to failure under load.

What is the difference between bar-and-plate and tube-and-fin intercoolers?

Bar-and-plate intercoolers use a stacked aluminum plate construction that is more durable and provides superior cooling efficiency but adds more weight. Tube-and-fin intercoolers are lighter and provide faster heat dissipation at the core surface but are less robust and can be damaged more easily by road debris. Bar-and-plate cores are the preferred choice for performance and motorsport applications where cooling capacity is the priority.

How do I size an intercooler for my build?

Intercooler sizing depends on horsepower target, boost pressure, and ambient conditions. A larger core provides more cooling capacity but can introduce lag on small-displacement engines with low-flow turbos. For street builds, a core 30 to 50 percent larger than OEM volume is a common starting point. Track and race builds running aggressive boost targets typically use the largest core that physically fits the chassis.

Browse related categories in our air intake systems, exhaust systems, suspension upgrades collections.