Selecting a charge air cooler (aka intercooler) has been made simple with the Intercooler core page. Each core has a horsepower rating, making it easy as matching your desired power target to the core. In general, use the largest core that will fit within the packaging constraints of the application.
Another important factor in selecting the correct intercooler is the end tank design. Proper manifold shape is critical in both minimizing charge air pressure drop and providing uniform flow distribution. Good manifold shapes minimize losses and provides even flow distribution. The over-the-top design can starve the top tubes, however. The side entry is ideal for both pressure drop and flow distribution, but it is usually not possible due to vehicle space limitations.
Proper mounting of the intercooler increases the durability of the system. Air to air charge air coolers are typically “soft-mounted”, meaning they use rubber isolation grommets. This type of mounting is also used for the entire cooling module. The design guards against vibration failure by providing damping of vibration loads. It also reduces thermal loads by providing for thermal expansion.
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