Intercooler

An intercooler cools the hot compressed air coming from the turbocharger before it enters the engine. Cooler air is denser, which means more oxygen and more power, and it also protects the engine from excessive intake temperatures.

Boost leaks are the common failure. A cracked intercooler, loose clamp, or split boot lets pressurized air escape, causing power loss and underboost codes. A pressure test of the charged air system finds leaks fast.

Mike Turner

Red Seal certified heavy duty mechanic with 14 years turning wrenches on Cummins, Powerstroke and Duramax engines across Alberta and Ontario. Mike writes the guides he wishes existed when he was apprenticing.