Abstract: A study on the internal flow and heat transfer in an air-to-air intercooler of a SUV is conducted by using 3D dual-stream model, the velocity field, temperature field and pressure field in the internal cold and heat flows of the intercooler under different driving conditions are analyzed, and the existence of eddy in internal flow field and the distribution of local high and low temperature and pressure areas are effectively predicted. The comparison results of the temperatures obtained by 1D, 3D, 1D/3D simulations and test verification show that among three simulation schemes, the 1D/3D co-simulation has highest accuracy, the results of 3D and 1D/3D simulations on temperature distribution are relatively close, and the relative error between 3D simulation and test is within 5%. The study verifies the feasibility of simulation with the dual-stream model for intercooler, providing references for enhancing engine intake efficiency and the research on the internal heat-transfer of intercooler

Key words: air-to-air intercooler, flow and heat transfer, dual stream model, 1D/3D simulation