HOW DOES A DIESEL INTERCOOLER WORK?
AIR = POWER
The compression of air into the cylinders is essential in all diesel engines. The more air, the more oxygen (O2)--which is the necessary component for combustion. Thus, the more O2 to help the fuel burn, the more power the engine will produce. That's why turbos are so important. Using the pressure from the engine's exhaust flow, the turbo's spinning turbines suck a higher volume of air through the intake and forcefully pack it into the cylinders.
BUT NOT ALL AIR IS THE SAME
The problem is, not all air is created equal. In a principle as known thermal expansion, the molecules that compose heated air move more wildly and become less dense. The hotter the air, the less O2 molecules per cubic foot. Because turbos tend to heat the air that moves through them, the air getting packed into the cylinders contains less O2 molecules and is therefore not as potent as it could be.
SO AN INTERCOOLER COOLS THE AIR TO PROVIDE HIGHER O2 DENSITY
By cooling the forced air that is output by the turbo before it reaches the cylinders, an intercooler increases the ratio of O2 that combusts with each stroke of the engine.
MORE O2 DENSITY = MORE POWER = HAPPIER DIESEL DRIVER
BD Diesel Performance