Does ZFG Recommend Intercooler upgrades?
Aftermarket Part:
Parts Category:
Other Names / Types:
Intercooler
Forced Induction
Innercooler, FMIC, Front mount, charge air cooler, heat exchanger
The Basics:
Optimized Performance:
Temperature regulation is crucial for power production and delivery. When engine or charge temperatures rise too high, your vehicle automatically limits power output to prevent damage. This applies to both stock and tuned vehicles.
Enhanced Efficiency:
Upgrading the stock intercooler helps maintain lower charge temperatures for extended periods. This means your engine can operate at peak efficiency for longer, minimizing power limitations due to high temperatures.
Recommended Modifications & Tune-Related Impact:
Recommended vs Required:
Upgrading the intercooler is not required for tuning. However, it is strongly recommended to maximize gains.
This modification will support maximum gains from tuning and any future modifications, like a cold air intake.
Upgraded intercoolers do not require a tune.
Adding one to a tuned vehicle does not require a tune update.
How it Works:
Types of Intercoolers
There are two main types of intercoolers:
Air-to-Air Intercoolers - Function: These intercoolers use ambient air to cool the compressed air. The hot compressed air passes through the intercooler, where it is cooled by the outside air flowing over the intercooler's fins and tubes.
Advantages: Simple design, no need for additional cooling systems, and effective in most driving conditions.
Disadvantages: Cooling efficiency depends on the vehicle's speed and ambient air temperature. The vehicle must be in motion for the inetrcooler to work.
Air-to-Water Intercoolers:Function: These intercoolers use water or coolant to cool the compressed air. The hot compressed air passes through the intercooler, where it is cooled by water circulating through a separate cooling system.
Advantages: More consistent cooling performance, less affected by ambient air temperature, and can be more compact.
Disadvantages: More complex design, requires additional components like a water pump and radiator, and can be heavier.
Working Principle
The intercooler operates by transferring heat from the compressed air to the cooling medium (air or water). Here’s a step-by-step overview of the process:
Compression: The turbocharger or supercharger compresses the intake air, increasing its temperature.
Heat Transfer: The hot compressed air flows through the intercooler, where heat is transferred from the air to the cooling medium.
Cooling: In an air-to-air intercooler, the heat is dissipated into the ambient air. In an air-to-water intercooler, the heat is absorbed by the water or coolant, which is then cooled by a radiator.
Delivery: The cooled, denser air is then delivered to the engine's intake manifold, where it mixes with fuel for combustion.
Explorer-Specific Recommendations:
High or excessive engine and charge temperatures are seen within ¼ mile of spirited driving on the stock intercooler. This is called heat soak.
When excessive temperatures are present, the engine automatically pulls power to prevent engine damage (this is called a ‘safety’). This happens with a stock or Custom Tune applied.
The benefits of tuning, and other mods, become null when heat soak sets in, and the safety is applied.
All of the available intercoolers provide adequate cooling for extended performance on stock and ZFG Tunes.
F150-Specific Recommendations:
Not all options for this platform are "direct fit" or "OEM Location." Please read product descriptions and installation instructions carefully before purchasing.