50-State compliant Intercoolers

[Brian_B]

Eventually, I'll need to replace my intercooler. It's not been super critical, but I've bashed the lower fins on mine.

I live in California. Intercoolers are on the CARB list of things that must be either OEM or certified. Now, I know there are a lot of people who get inspected without CARB certified stuff all the time. I don't plan on being so lucky, and want the inspection to just go without needing to worry about it. So I'm only looking at CARB-compliant options.

There are a lot of intercooler threads - most devolve pretty quickly, so I'm not bumping any of them.

I'm only interested in options that have CARB certification. You may have had a great experience with a certain brand, but if it doesn't have a cert, I'm not too interested right now.

To clarify, because the great vendors here love to chime in on the details when they smell blood in the water - I'm not looking to buy immediately. To be honest, probably not until this wheeling season is over, but I do want to start my research. I have a ProCal tune now, although since swapping out the exhaust and gearing I do tend to accidently flip the blowoff in 3rd gear quite frequently, so I dunno if I should be looking at an additional tune to go with it or not.

To date, I'm only aware of 3 options:
Go back with OEM - about $300
Whipple - about $900
Cobb - about $1000

Are there other options I'm missing (that are CARB certified)? I know there are a lot of intercooler options out there, but CA-compliant seems to really cut down the list quickly.

Both Cobb and Whipple look pretty similar - are there any advantages to one over the other?

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[Dave2020GT]

To be honest if its quite hidden, which they usually are, I don't think you would have any issues with an intercooler. I live in Cali myself. Just get one in black and it pretty much fits in the OEM location. There are quite a few more options than just those. I believe Mishimoto makes one as well as Panda Motorsports. I think what could be a clue of an updated intercooler are the charge pipes.

I would probably lean toward the Whipple, it does have a CARB number.

 

[Oldhippie]

I am also in Calif and need CARB approved stuff…don’t know of any approved intercoolers other than Cobb & Whipple either…I would also like to know about any approved downpipes also…I don’t know about any…those are the two items I am thinking about doing for alittle unnecessary performance gain to my 2.7 to throw away some of my extra money…

 

[Returntothefog]

CARB do be a pain but the price we pay for better quality air I suppose. I believe the whipple one edges Cobb out slightly (spec wise), but the difference is not big.
I think unfortunately it is similar to the intake situation where the options are plenty, but CARB legal ones are few…
(Case of intake it’s only Cobb and roush and they are basically just bigger filters)

 

[Returntothefog]

I am also in Calif and need CARB approved stuff…don’t know of any approved intercoolers other than Cobb & Whipple either…I would also like to know about any approved downpipes also…I don’t know about any…those are the two items I am thinking about doing for alittle unnecessary performance gain to my 2.7 to throw away some of my extra money…

I believe the days of California legal downpipes are behind us…

 

[Felix808]

Wow, didn't know about intercoolers being on the list, but not surprising considering CARB . I was going to suggest Whipple as well as I have a CARB sticker for their Stage 1 .

 

[Q1svt]

Both Cobb and Whipple look pretty similar - are there any advantages to one over the other?

They both are coated [powder coating?] that will reduce there ability to cool... OEM for stock engines

Hope @Beach_Bum old post about a Ford hidden winch comes true cause ford will need a different intercooler and placement ... maybe a better one for the RTR...

 

[Brian_B]

They both are coated [powder coating?] that will reduce there ability to cool... OEM for stock engines

You can get both the Cobb/Whipple in either bare aluminum or powder coated I believe.

And even powder coated, the increase in surface area is pretty substantial over stock. Not sure how those offset each other though. You make a good point about stock engines not really benefitting over either aftermarket options though.

 

[Q1svt]

If you read the fine print... neither changed the frontal area... just made them thicker,

Once the air entering the front is heated, it's not going to absorb any more heat ;^) no matter how thick the additional IC is ... law of thermodynamics

• 23% Increased Cooling Efficiency [neither provided any 'proof' ]
• 53% Larger Volume [ but not frontal area...]
• No cutting, trimming, or permanent modification to the vehicle required
• Mates up snugly to OEM shutter shroud to funnel air through ambient side fins like OEM
  

 

[burgerking]

I've regretted some mods but the intercooler is not one of them

 

[Brian_B]

If you read the fine print... neither changed the frontal area... just made them thicker,

You know, not even gonna argue with you.

 

[Willub]

You know, not even gonna argue with you.

 

[Bronco21Maybe]

What's an intercooler?

 

[Q1svt]

@Willub why didn’t you and Grayxyz tell / teach @Brian_B how turbo & intercoolers work?​

oh yeah cause you haven’t figured it out yet lol​

 

[Q1svt]

@Brian_B if you are truly interested in this subject.. Garett is the turbo king here are just a couple of their technical documents
Key Design Considerations

• Size and Airflow: An intercooler that is too large can introduce turbo lag, while one that is too small cannot effectively cool the air.
• End Tank Design: Cast aluminum end tanks are typically preferred for strength, while CAD-modeled designs help maximize airflow and minimize pressure drop.
• Fin Density: A higher fin density improves heat transfer but can restrict airflow, requiring a balance.
• Mounting: Front-mount (FMIC) designs offer the best cooling due to direct airflow, while top-mount (TMIC) designs can suffer from heat soak.

https://www.garrettmotion.com/news/...ler-sizing-and-end-tank-design-with-rob-dahm/



https://www.garrettmotion.com/knowl...bo-replacement/intercoolers-how-do-they-work/



https://www.garrettmotion.com/knowl...ement/turbo-lag-causes-effects-and-solutions/



https://blog.edgeautosport.com/what...n Explained,cheaper and easier to manufacture.



https://official.bankspower.com/magazine/the-science-of-intercoolers/

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