DIY Liquid Intercooler

Liquid intercoolers help add power to a car's engine.

Superchargers and turbochargers add extra thrust to a car engine's performance, aiding in acceleration and overall power. However, both charger types heat air that must enter the vehicle's engine for combustion. The heat reduces the amount of oxygen molecules entering the engine, lowering power output. A liquid intercooler reduces the temperature of the heated air before it enters the engine, increasing power. A DIYer can build a liquid intercooler system with a few key components.

Things You'll Need

• Air-to-water intercooler
• Screws
• Screwdriver
• Heat exchanger
• Intercooler pump
• Intercooler water lines
• Ring clamps
• Nuts
• Nut driver

Instructions

1. Install the air-to-water intercooler, or liquid intercooler, between the supercharger and the engine's air intake manifold. Secure the intercooler against an open surface, such as the engine's side wall, using screws and a screwdriver.

2. Attach the supercharger's air output hose to the intercooler's input opening. Connect the intake manifold's input opening to the intercooler's output slot. Secure both attachments with ring clamps.

3. Install the heat exchanger near or behind the vehicle's radiator, commonly at the front of the engine well. Secure the heat exchanger with nuts using a nut driver.

4. Connect a water line between the intercooler's liquid input opening and the heat exchanger's output slot. Secure with ring clamps.

5. Install the intercooler pump between the heat exchanger and the intercooler. Secure the pump to an open engine surface using screws and a screwdriver.

6. Attach a water line between the pump's input slot and the intercooler's liquid output opening. Connect a water line between the pump's output opening and the heat exchanger's input opening. Secure all connections with ring clamps.

7. Start the engine and test the intercooler's performance while driving.

Tips & Warnings

• Use caution while working within the car's engine. Disconnect the car's battery to prevent any accidental electrocutions.

References

• Engine Basics: What is an Intercooler?
• Engine Basics: Building a Competitive Air to Water Intercooler System