Top Intercooler Upgrades for SR20DET Engines

Understanding the SR20DET Engine

The SR20DET is a popular 2.0L turbocharged engine designed by Nissan that has developed a strong following among tuners and racing enthusiasts. This four-cylinder engine was produced from 1989 to 2002 and featured an aluminum head and block, double overhead cams, and both direct and port fuel injection depending on the variant.

In stock form, the SR20DET generated anywhere from 200 to 250 horsepower depending on the exact specs. However, this engine responds incredibly well to modifications and is capable of generating significantly more power when equipped with upgraded turbochargers, intercoolers, intake and exhaust systems, engine management systems, and supporting mods.

The Importance of Intercoolers on Turbocharged Engines

One of the most important modifications for any turbocharged engine is the addition of an aftermarket intercooler. The factory intercooler on SR20DET engines is rather small and inefficient. Upgrading to a larger and more efficient front-mount intercooler makes a dramatic difference in performance.

Intercoolers serve to cool the intake air after it passes through the turbocharger. Turbochargers dramatically increase air temperature. Cooler air is denser and allows more oxygen into the combustion chamber, increasing power production. An upgraded intercooler provides consistent intake temperatures, protecting the engine from heat soak.

Design Considerations for SR20DET Intercoolers

There are several important factors to evaluate when selecting an aftermarket intercooler for your SR20DET:

• Size - Bigger is generally better as it provides more cooling capacity. Make sure to measure your engine bay for fitment.
• Materials - Bar-and-plate and tube-and-fin are common designs in various materials. Aluminum offers a good balance of cooling, cost and weight.
• Efficiency - Densely packed fins and tubes with minimal pressure drops across the system.
• Air Flow Design - Smooth internal surfaces to allow unobstructed airflow are essential.
• Strength - Durable end tanks and thick cores capable of withstanding boost pressures.
• Fitting Compatibility - Ensure your piping can easily mount to the inlet and outlet openings.

Top Intercooler Options for SR20DET Engines

When tuned properly with supporting mods, the SR20DET engine is capable of generating 400+ horsepower. Here are some of the most popular intercooler options among enthusiasts wanting max power:

CUSCO Front Mount Intercooler Kit

This bar-and-plate intercooler from CUSCO is one of the largest universal kits capable of fitting the SR20DET engine bay. It features a lightweight aluminum construction, acutely angled end tanks to promote smooth airflow, and a fin density of 12 fins per inch for maximized cooling capacity.

Many owners run this intercooler along with a large front-mount turbo upgrade and report intake temperatures nearly 50°F lower than stock along with 80-150hp gains. The only downside is that it sits close to the ground, so a front splitter should be added to prevent debris damage.

Tomei Type-A Intercooler

Tomei is well known in the Nissan aftermarket world for their turbochargers, but they also produce race-spec intercoolers like this Type-A kit. It has an efficient bar-and-plate core along with compact end tanks to fit into tight engine bays.

Outstanding construction quality featuring 100% aluminum throughout makes it both durable and lightweight. It can support over 500hp while actually weighing less than the factory Nissan unit. Excellent cooling performance despite its small size make this a popular option.

AMS Performance Race Intercooler

For those looking to minimize intake temperatures, the AMS Performance front-mount race intercooler is an excellent choice. It utilizes a thick core and extra-dense fin packing to maximize heat dissipation. The compact end tanks also use a V-band mounting system for a reliable seal.

Many owners end up needing to customize or relocate parts to get this unit to fit, so it does require some additional work. But once properly mounted, it's capable of keeping intake temps near ambient even on high horsepower SR20DET builds.

Other Notable Brands

Those are three of the most popular choices, but companies like GReddy, HKS Racing, Mishimoto, TRUST and even eBay generics also produce capable intercoolers for the SR20DET platform. As long as you select the proper size and materials based on your power goals, most options will offer substantial cooling improvements.

Just keep in mind cheaper options may have less efficient fin designs, weaker end tanks, and poorer construction quality. This can negatively impact cooling capacity while also being more prone to leaks or failure when subjected to higher boost pressures.

Supporting Modifications

While the intercooler itself is critical for unlocking more power from an SR20DET engine, you’ll also need supporting mods like enhanced turbochargers, free-flowing intake and downpipes, high-flow fuel injectors and pumps, and of course, a professional engine tune.

With the right complementary modifications, that larger front-mount intercooler can help take your SR20DET’s output to the next level. Just make sure to select components like turbos and fuel systems based on your target horsepower number.

And don’t forget engine health mods as well - upgraded oil pumps, cooling systems and quality internal components are a must when raising power substantially. Taking the time to build your SR20 properly ensures you can enjoy that extra output for years to come!

FAQs

What size intercooler do I need for my SR20DET?

At a minimum, an upgrade to 600x300x76mm is recommended to support over 300hp. For 400-500hp goals, look for a core around 800x300x102mm. And for maximum power over 500hp, a race intercooler with 1000x400x76mm capacity or more is ideal.

Should I get a front mount or top mount intercooler?

Front mount intercoolers are vastly superior for cooling efficiency and are strongly recommended. Top mount intercooler leave the intake piping with tight bends which restricts airflow. They are also more prone to heat soak issues.

How much boost drop should I expect across an intercooler?

With a well-designed intercooler upgrade, you can expect a boost pressure drop of just 1-3 psi. More restrictive intercooler cores can see 5+ psi drops which negatively impacts performance. So make sure any intercooler under consideration has efficient, smooth end tanks.

Can I reuse my stock intercooler piping with an upgrade?

Sometimes yes, but typically upgraded front mount intercoolers have different inlet/outlet sizes, angles, and locations compared to the stock side-mount intercoolers. Custom or pre-bent replacement piping matched to the new intercooler is recommended for best results.