Charge Air Coolers in Calgary

How Does the Cooling System Work?

The charge air cooler works on the same principle as radiators or heat exchangers. Air on its way to the engine first passes through the turbocharger, where it is compressed using exhaust gases. The compression of the air increases its temperature. 

A charge air cooler is used to bring down the temperature of the air before it enters the engine for combustion.

Charge air coolers, also known as air-to-air coolers, work by transferring heat from hot compressed air to cooler ambient air. Hot air travels through tubes within the cooler, while cooler air flows over the outside of those tubes. This efficient design allows the heat to be dissipated from the compressed air, significantly lowering its temperature.

These units are made of materials that qualify as good conductors. Therefore, when hot air passes through these charge air coolers, the heat is dissipated, and the air is cooled down.

Thus, a charge air cooler effectively cools the engine inlet air for improved fuel combustion.

Do Charge Air Coolers Need Replacement?

Wear and tear, breakdown, and failure are common to charge air coolers, just as they are to every other engine component. Air cooler leaks are the primary reasons for the failure of charge air coolers. In the case of leaks, every engine’s performance and fuel efficiency are severely impacted.

In some cases, engine horsepower can even decrease by 50%. To prevent such inefficiency, the replacement of the charge air cooler becomes important.

Detecting a leak in the charge air cooler can be difficult. Some signs that point to a possible failure of the unit include: 

• Increased fuel consumption
• Increased particulate emissions
• Increased temperature of coolants
• Failure of the turbocharger
• Massive horsepower loss

The constant exposure to stress, vibrations, and overheating takes a toll on the charge air cooler units and causes failure. Most charge air coolers need to be replaced every 3 to 5 years.