Replacement Intercooler Hoses & Pipes

Turbochargers force more air into an engine’s cylinders than atmospheric pressure alone can. More air equals more oxygen, which can be mixed with a larger amount of fuel, and when this mixture burns, combustion pressure is increased, resulting in more power. However, compressing the air also raises its temperature, and the increased cylinder pressure and air temperature must be properly regulated to prevent engine damage. Boost pressure is controlled by the wastegate and a bypass or blow-off valve, and the intercooler keeps the air intake charge within the ideal temperature range.

A turbocharger consists of a turbine wheel and a compressor wheel that rotate on a common shaft in an aluminum housing. The turbine wheel is plumbed into the exhaust system and exhaust flow spins the turbine blades, which in turn drives the compressor wheel. The compressor section of the turbo is part of the air intake system. Air is drawn through the air filter and intake tube, compressed by the compressor wheel and forced into the intake manifold. But, if this hot pressurized air is allowed to enter the cylinders fresh from the turbocharger, it could cause engine damaging detonation.

To cool the hot compressed air, the intake air charge is routed from the turbocharger outlet through an intercooler, and then to the intake manifold. An intercooler lowers the air temperature, which increases its density and oxygen content for an even greater increase in power and resistance to engine knock. An intercooler enables the benefit provided by the turbocharger, without the dangers and inefficiency that can result from heat. Not all older turbocharged vehicles had intercoolers, but today they are a part of most factory turbocharger setups, so the vehicle manufacturer can ensure performance with durability.

There are air-to-air and air-to-water, sometimes called air-to-liquid, intercoolers, with the former being the more common type. Air-to-air intercoolers resemble radiators, function in the same way, and are typically mounted in the same area of the vehicle so they can be exposed to airflow through the grille. However instead of engine coolant, it is the hot compressed intake air charge that flows through the intercooler. The heat from the intake air is transferred to cooling fins and then to the ambient air that passes through the intercooler. Air-to-air intercoolers are commonly used with turbochargers and centrifugal superchargers, while air-to-water intercoolers are positioned between the supercharger and intake manifold with Roots type and screw type superchargers.

The turbocharger and intake manifold are connected to the intercooler with a system of hoses and pipes. Because they have to deal with extreme heat, these hoses are typically made of silicone or EPDM (Ethylene Propylene Diene Monomer) rubber. The pipes are constructed from metal or plastic and connected to the turbo, intercooler, and intake manifold with couplers, commonly known as boots, which are made from the same material as the hoses. The boots provide the flexibility that is needed to accommodate the chassis-mounted intercooler and the engine and engine-mounted turbocharger that can shift on the motor mounts in response to engine torque. The boots prevent cracks and breakage that would result from rigid mounting.

Nevertheless, age, heat and exposure to chemicals like engine oil can eventually take a toll on hoses and boots, causing hardening, cracks and tears. Symptoms of faulty intercooler hoses and pipes include reduced power, knock and increased fuel consumption, which can be caused by leaks and poor sealing. Leaks can result in reduced pressure and incorrect air/fuel mixture. If you’re experiencing performance problems caused by failed intercooler hoses, pipes, or boots, we have the replacement parts that will restore proper vehicle operation and preserve your engine. Our replacement hoses and pipes are manufactured to OE size, shape and material specifications, so you can be assured of precise dimensions for easy fitment. In addition to hoses, pipes and boots, we offer boot kits, clamps, hoses that come with clamps, intercooler resonators, and complete intake systems.