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Updated: Jun 26

Image Source: HP Diesel. Link to the image

Adding an aftermarket intercooler when dyno tuning or remapping a diesel engine offers several advantages that can significantly enhance performance and reliability. Here are some key reasons:

1. Improved Air Density

An aftermarket intercooler provides better cooling of the intake air. Cooler air is denser, which means more oxygen molecules are available for combustion. This leads to a more efficient and powerful combustion process, improving overall engine performance.

Additionally, when you compress air, the air temperature increases. Thus, increasing turbo boost pressure with remapping and tuning can cause a factory intercooler to reach a point of inefficiency.

2. Enhanced Power Output

By reducing the intake air temperature, an aftermarket intercooler allows for higher boost pressures and more aggressive tuning. This can result in significant gains in horsepower and torque, making the vehicle more responsive and powerful.

3. Increased Reliability and Longevity

Keeping the intake air temperature in check reduces thermal stress on engine components, such as pistons, valves, and the turbocharger. This can enhance the overall reliability and longevity of the engine, especially under high-performance conditions.

4. Consistent Performance

Stock intercoolers often suffer from heat soak during prolonged periods of high performance, leading to reduced efficiency. Aftermarket intercoolers typically have larger cores and more efficient designs, maintaining consistent performance even during extended periods of aggressive driving.

5 Better Fuel Efficiency

Improved combustion efficiency can lead to better fuel economy, as the engine can produce the same power with less fuel. This can be particularly beneficial for diesel engines, which are often used in applications where fuel efficiency is critical.

6. Support for Future Upgrades

If you plan on further modifications in the future, such as a larger turbocharger or more aggressive remapping, an aftermarket intercooler provides the necessary headroom to handle increased power levels without compromising reliability.

By addressing the heat-related challenges associated with higher power outputs, an aftermarket intercooler becomes a valuable investment for anyone looking to maximize the benefits of dyno tuning or remapping their diesel engine.

Disclaimer: The information provided about aftermarket intercoolers is for general guidance only. Actual performance gains and reliability improvements may vary based on specific vehicle conditions and usage. Always consult with a professional before making any modifications to your vehicle. TechTune Performance is not liable for any damages or losses resulting from the use of this information.

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