Following on from our very successful intercooler for the RS3 8v chassis, the Forge intercooler for the TTRS (8S) chassis builds on our reputation for delivering cores that offer real-world increases in power and temperature drops. Whilst the 8V chassis shares many components with the TTRS 8S, the space available behind the bumper is a different shape and the crash bar has also changed. This required a whole new intercooler and crash bar setup for this latest chassis.

The TTRS core is a huge 640x250x100 and of bar and plate design. This gives it a huge 56% more surface area than stock, and an even more impressive 94% increase in volume. The end tanks are made with integrated pipes in order to retain the stock boost hoses, though you can also replace the hoses with our FMKT024 boost hose set if you so wish. Just like on the 8V chassis, we supply a genuine Audi TTRS crash bar which we modify in house in order to accept the new larger core, then finish both the crash bar and core in our standard black crackle finish powder coat for maximum longevity.

As shown in the graph above, for both tests we let the car heatsoak on the dyno until the radiator fans tripped on and off (which gives an inlet temperature of 36°C), then did a dyno pull from there. This gives a more consistent result and reflects real-world driving conditions more accurately. You can easily see the Forge intercooler cools much quicker and delivers a much greater drop in temperature compared to OEM.

On the stage 1 car we tested on (with map and exhaust modifications), it made 470.5 bhp with a peak intake temperature of 76°C. With just this intercooler fitted and no other modifications, the same car made 520.8 bhp with a peak inlet temperature of 34°C, a gain of 50 bhp and a drop of 41°C. Gains on stage 2 mapped cars will likely be even more impressive as the stock intercooler core really starts to struggle on just stage 1 mapped cars.

The kit contains everything needed for installation including full fitting instructions, which should take around 3-4 hours.

Technical Data

As part of our expanding Audi product range, AIRTEC Motorsport is proud to launch our RS6 C8 intercooler upgrades suitable for track or fast road use.

In order to ensure there is no noticeable loss in performance during extended periods of hard driving, we have developed larger capacity, freer-flowing intercoolers to replace the smaller and more restrictive OEM items.

The original twin intercoolers are mounted between the bumper and inner arch liners and utilise designated air guides on both the front and back to help direct air to and from the intercooler effectively. Wishing to keep these in place, we opted to concentrate on creating a new core design that was the same width and height but deeper to help increase cooling ability.

The result are direct replacement intercoolers that reuse all the original hoses, mounting points and air guides for simplicity but offer a huge 21% increase in overall capacity in comparison to the OEM intercoolers.

Together with our high-flow end tanks to ensure internal flow is directed correctly and efficiently, the AIRTEC Motorsport intercooler upgrades offer greater cooling efficiency and volume over standard. 

The kit reuses all original fixings and includes detailed installation instructions for a simple and effective cooling solution. 

TESTED
Data logging of the turbo outlet/pre-intercooler temperatures and the post intercooler air temperatures showed the AIRTEC Motorsport uprated intercoolers maintained a steady rate with no abnormal spikes, despite the turbo temperature seeing a dramatic rise of nearly 170% in a short amount of time. 
In comparison, the original intercoolers were also logged and when the data overlaid, it highlighted they weren’t able to resist the temperature spike as well, seeing a rise of 60% over the AIRTEC intercoolers.   

Features: 

• 21% increase in capacity compared to original intercoolers
• Tested against original and proven increase in cooling ability
• Reduced charge temperatures
• High-flow, cast end tanks
• Powder-coated black finish
• Reuses all original mountings points and fixings
• Features detailed fitting guide

Registered Design Right number: Application Pending 

AIRTEC part no: ATINTVAG47

RacingLine’s MQB ‘Evo’ intercooler unit features a high-speed core using extra tall internal tubes for maximum boost flow and a massive 96% increase in volume.

Cast construction end tanks ensure minimal turbulence and restriction with internal flow guides to divert airflow up and down across the entire core depth, with enlarged 70mm inlet & outlet (versus 60mm for the OE cooler).

These increased 70mm inlet and outlet sizes allow for higher flow versus the smaller factory outlets, with matching Boost Hoses provided with the intercooler kit. These Boost Hoses are reinforced, internally-wired, multi-ply construction to resist heat deformation and burst pressure. They are moulded with internal steps to maximise laminar airflow. Supplied with stainless steel Mikalor-brand clamps.

Our development focussed on finding the ‘sweet spot’ of maximum IAT cooling versus minimum pressure loss. This has allowed us to achieve increased size without increased lag.

By consistently reducing intake air temperatures (IAT), heat soak is minimised delivering increased performance again and again. No need for the recovery cool-down times needed for the production intercooler.

An essential upgrade to any 2.0 TSI MQB ‘Evo’ car.

After much research, development and testing at AIRTEC HQ, our intercooler upgrade for the VW Polo Mk6 1.8 TSI has been added to our ever-growing range of products. Built using a high flow core to offer increased cooling efficiency and performance, we take pride ensuring all of our kits are finished to our usual high standard and premium quality. Designed in the UK and offered at a reasonable price.

Great addition to any standard or remapped Polos.

Dimensions:
Width: 800mm

Height: 300mm

Depth: 80mm to 60mm stepped core

Features:

• Stepped intercooler core 80mm bottom section and 60mm top section, with flowed cast end tanks, this means less welding and a stronger intercooler
• Unbeatable value for money
• Proven power increase for fast road & track builds
• Available in Pro-Series Black or Natural Silver
• AIRTEC 3-year unlimited mileage warranty
• Fitting will take 3-4 hours depending on mechanical skill
• Fits to standard OEM hoses

Registered Design Right number: 6023913

AIRTEC Part No: ATINTVAG33

RacingLine’s High Performance ‘Plate & Bar’ Stepped Intercooler for Polo GTI AW & AW.2 will deliver lovely cool intake air temperatures for your 2.0 TSI EA888 gen.3B or gen.4 Polo, again and again.
RacingLine’s massive ‘plate & bar’ Intercooler is one of the best performing intercooler upgrades on offer for the Polo AW. Its massive ‘Plate & Bar’ stepped core gives a mighty 56% increase in core volume over stock. It features a high-speed core using extra tall internal tubes for maximum boost flow, minimising the typical lag increase that often results from running such a big cooler.

Fitment is specific for the Polo GTI AW & Audi A1 GB 40TFSI – meaning no cutting or drilling is required to fit, and it’s carefully designed to retain and fit around the car’s original front crash bar without modification. The discreet ‘R-Bar’ stamping in the top surface is the perfect finishing touch. This careful fitment and stepped core design has allowed an increased frontal area of an impressive 25% versus the factory cooler.

RacingLine’s development focussed on finding the ‘sweet spot’ of maximum IAT cooling versus minimum pressure loss. Cast end tank construction ensures minimal turbulence and restriction to deliver maximum flow across the entire stepped-core’s depth.
Intercooler outlets are 60mm – meaning the stock boost pipes can be retained, or for optimum performance, RacingLine’s Polo GTI AW upgraded boost pipe kit is the ideal complement and fits with this intercooler perfectly.

By consistently reducing intake air temperatures (IAT), heat soak is minimised to deliver increased performance again and again. No need for the recovery cool-down times that the production intercooler requires.
This track-proven intercooler really is essential for every stage of tuning on any Polo GTI AW or AW.2 with 2.0 TSI EA888 engine (in either Gen.3B for AW or Gen.4 for AW.2).

Confirmed Applications:
– Audi A1 (GB) 40 TFSI – 2017+
– VW Polo (AW) GTI – 2017-2021
– VW Polo (AW) GTI – 2021+

CSF’s industry-leading reputation and deep knowledge of high-performance BMW cooling systems is second to none. CSF is proud to announce its new halo product, the “Level-Up” Charge-Air-Cooler Manifold for the 2021+ G8X M3/M4 platform. CSF set out to create a charge-air manifold that would not only match the S58 engine performance, but take it to a whole other level with its ultra high performance features and durability.

DESIGN, ENGINEERING, AND DEVELOPMENT

CSF worked closely with its strategic manufacturing partner PWR and Local R&D Partner Studio RSR on the development of the “Level-Up” Charge-Air-Cooler Manifold. The relationship with PWR offers CSF access to exclusive cutting edge Formula 1 grade technology, while Studio RSR offers expertise in real world race experience and hands on mechanical knowledge of the G8X platform.

There are many engineering details CSF isn’t ready to divulge prior to the official release. However, there is still a lot of information to share and details to be seen.

KEY FEATURES

BILLET CONSTRUCTION & PWR CORE

The manifold is fully made from the highest grade billet aluminum. Each part is CNC machined with the highest precision and TIG welded to form a single air-to-water charge-air-cooler that is integrated into the intake manifold. The CSF manifold is not only capable of achieving the highest levels of performance of the s58 engine, but it’s all metal design is capable of withstanding extreme boost levels.

The ultra high performance liquid-to-air core is made by PWR. This Bar & Plate core is pressure tested to 120 psi to ensure it will withstand the high boost levels motorsports race teams can throw at it. Feedback from the community has shown the OEM core which is crimped onto plastic end tanks is prone to failure starting at just 27 pounds (psi) of boost pressure.

 

FUEL AND NITROUS

Adding power always requires more fuel. Similar to the industries best selling B58 “Super Manifold” (CSF #8200), the G8X M3/M4 S58 “Level-Up” Manifold features a top feed port injection system. The injector bungs are machined directly into the intake runners. The kit includes both the Fuel Rail and CNC Machined Block-Off Caps for non-use.

 

In addition, the manifold also has integrated ports on each runner for Nitrous or Methanol Injection. Individual ports for each runner allows for maximum control and tuning.

G8X M3/M4 “LEVEL-UP” CHARGE-AIR-COOLER MANIFOLD FEATURES (CSF #8233/8233B/8233C)

• Faster recovery of Intake Air Temperatures (IATs)
• ~30°F reduction of Intake Air Temperatures (IATs) compared to OEM
• Less pressure drop compared to OEM core
  • Puts less stress on the turbo system, allowing more boost to be made at higher target power levels
• Ultra strong CNC Billet construction replaces weak plastic tanks with crimped-on gasket sealing core.
• High performance bar/plate intercooler core by PWR pressure tested to 120psi
  • OEM cooler is a tube/fin core which is prone to failing at pressures over ~27psi
• Top feed port injection w/ included fuel rail (w/ CNC machined block-off caps included for non-use)
• Integrated Nitrous/Methanol Injection Ports
  • Individual ports for each runner for maximum control
• Integrated vacuum and parameter pad to measure additional parameters
• Easy access to spin-off oil filter
• Integrated breather port for easy bleeding of air from the water side of the manifold
• Included KIYLEX Thermal Rejection Manifold Spacer
  • Made from KIYLEX® – A patented revolutionary high-performance final stage polymer
  • Acts as a thermal barrier that dissipates heat between the cylinder head and intake manifold
  • Proven to lower intake manifold temperatures by up to 15%
  • Lowers Intake Air Temps (IATs)
• All necessary brackets, hardware, and instructions to install
• Raw Billet Aluminum Finish (#8233)
• Thermal Black Heat Dispersion Powder-Coating Finish (#8233B)
• Available in custom colors from the leader in BMW cooling customization (#8233C)
• True Plug-and-Play “Drop-in Fit” Installation – Requires Absolutely No Modifications.
• OEM level of fit and finish
• Limited Lifetime Warranty

FINISHES

1. 8233 is the ‘standard finish’ in raw aluminium
2. 8233B is a special thermal dispersion coating which helps with dissipating heat (current images are of a different product, used to illustrate the finish)

CSF’s strategic partnership with PWR brings F1 cooling design and technology to the high-performance aftermarket. These intercoolers help to keep charge temperatures consistently lower than the factory intercooler. This is because your factory intercooler was designed for standard power levels and expected type of use, as soon as you go outside of the factory power levels and expected type of use, your factory intercooler will begin to struggle. As well as this, as your intercooler goes through its life the core will deteriorate externally as well as fill with contaminates internally which results in a reduction in its performance.  

Over time the factory plastic end-tanks which are crimped onto the factory core can leak, losing precious boost pressure resulting in a significant lack of performance and risk to the engine. 

However, not all intercoolers are made equal. 

CSF CORE DESIGN – ROLLED TUBE & BILLET END TANKS

The CSF intercooler for the FERRARI 488, PISTA & F8 is a larger, more efficient intercooler for significantly improved cooling power. 

PWRs rolled tube cores are optimised in PWRs in-house wind tunnel, through this process PWR select the optimum stack height and multi-louvred fin design for both the ambient and pressure sides for optimum balance between cooling power and pressure drop.

Benefits

• Eliminates heat soak
• Lowers charge air temperatures
• Eliminates end-tank failure at elevated boost levels

Features

• Sold as a pair (Left & Right Intercoolers)
• Eliminates Heat Soak and Lower Intake Air Temperatures (IATs) for Maximum Performance in High-Performance and Race Conditions
• Formula-1 Performance Grade Cores by PWR (2-Row Cores features Rolled Tubes w/ Inner Fins)
• 100% TIG Welded CNC Machined Billet End Tanks for Maximum Strength & Durability
• Made in the USA at PWR North America
• OEM Style Inlet/Outlet Connections for Precise Fitment With All OEM Components
• Available in Black Thermal Dispersion Ceramic Coating upon request
• Precision machined integrated BPV/BOV connection
• High-density foam installed for OEM Fit & Finish
• Integrated OEM Style Fan Shroud
• True Plug-and-Play “Drop-in Fit” Installation – Requires Absolutely No Modifications
  • Additional installation steps for 488 Pista/F8 – Instruction Guide Download (Click Here)
• R&D and Performance Testing by Industry-Leading Tuning Companies M-Engineering, World Motorsports, and Voodoo Design

CSF MANUFACTURING, TESTING & FINISH

These intercoolers are manufactured PWRs North American factory, this means PWR has total control over our production, unlike other white-label brands. PWR’s intercoolers start life in their factory as an aluminium sheet or bar and from there they create their own rolled tubes, multi-louvred fins, CNC machine all of the fittings. The core is then CAB brazed in their state of the art clean room and the end-tanks and fittings TIG welded together by their master welders. 

All of PWR’s intercoolers are individually leak tested and go through a fitment inspection to ensure critical dimensions are per our design. 

To finish our intercoolers are only available in a raw finish.

• OEM Part Numbers:
  • Ferrari 488 GTB/Spider: 328422 (right) | 328423 (left)
  • Ferrari 488 Pista/Pista Spider: 748559 (right) | 748562 (left)
  • Ferrari F8 Tributo/Spider: 748559 (right) | 748562 (left)

• Applications:
  • 2016-2019 Ferrari 488 GTB
  • 2016-2019 Ferrari 488 Spider
  • 2019-2021 Ferrari 488 Pista
  • 2019-2021 Ferrari 488 Pista Spider
  • 2020+ Ferrari F8 Tributo
  • 2020+ Ferrari F8 Spider

Experience the ultimate performance upgrade for your Hyundai i30 N with the impressive WAGNERTUNING high performance intercooler.

Specifically designed to meet the demanding requirements of the Hyundai i30 N, this intercooler features a new type of competition intercooler core (Tube Fin) that impresses with dimensions of 580 mm x 150 mm x 135.4 mm + 580 mm x 62 mm amounts x 70 mm (stepped core: 14.3 liters). With a 44.3% larger face area and 101.4% larger net volume compared to the original intercooler, this high performance core offers unmatched performance.

Made of high-quality cast aluminium, the end boxes were CAD-designed and optimised using CFD simulations to ensure ideal internal airflow. The result is outstanding cooling characteristics with minimal back pressure. In addition, the innovative performance high performance intercooler core allows for adequate airflow to adjacent components such as the water cooler through the use of a custom air baffle. This kit is thus perfectly suited for racing and provides optimal cooling of the supercharged air with a significant increase in performance.

With an anti-corrosion coating that has outstanding heat conduction properties, the WAGNERTUNING intercoolers are optimally protected from environmental influences and offer a lasting and efficient cooling effect. Installation is effortless at the original mounting points and is easy to perform thanks to the plug-and-play system. Like all our products, this intercooler is subject to strict qualitative monitoring.

With an inlet and outlet diameter of Ø65mm, this intercooler allows for optimal flow and contributes to an impressive increase in the performance of your Hyundai i30 N. Take your vehicle to a new level and experience the full power that this high performance intercooler offers. Boost your performance and dominate the road like never before.

Fits the following model:
Hyundai I30 N Performance 206KW/280HP (2021+)

core dimensions OEM intercooler:
V = 7,1 L
A = 79360 mm²

core dimensions WAGNER TUNING intercooler:
V = 14,3 L
A = 114492 mm²
G = 9,3kg

Part number: 200001186
Comes with:
1 intercooler
2 silicone hoses
1 air baffle
1 mounting material
1 installation instruction

TECHNICAL DATA

Suitble for DCT and Manual

As part of our expanding Hyundai product range, AIRTEC Motorsport is proud to launch our intercooler upgrade for the facelifted (2021 onwards) i30N suitable for track or fast road use.

In order to ensure there is no noticeable loss in performance during extended periods of hard driving, we have developed a larger, freer-flowing intercooler that is a direct replacement for the smaller and more restrictive OEM item.

Our solution to increasing the intercooler’s size and performance within the confines of the limited space behind the bumper is based upon a stepped twin-core design l with increased depth. This offers an increase in overall capacity in comparison to the original intercooler, as well as a substantial increase in frontal area over standard, which allows it to make the most of the air flow provided.

Together with our high-flow, moulded one-piece cast end tanks to ensure flow is directed correctly and efficiently, the AIRTEC Motorsport intercooler offers much greater efficiency and volume over standard.

With a 70mm cold side, this makes the AIRTEC Motorsport intercooler the largest on the market currently for the Hyundai i30N!

Despite this improvement, it fits neatly behind the original bumper, requires no trimming or cutting. The comprehensive fitting kit includes all the correct fixtures and fittings, step-by-step instructions with pictures, new Pro Hoses silicone hoses and should take around 2-3 hours to complete.

The intercooler is available in Pro-Series Black finish and either with or without the AIRTEC Motorsport logo and Gloss Black Pro silicone hoses.

Intercooler test data:

Features:

• Stepped intercooler design for maximum flow
• Designed and manufactured in the UK by AIRTEC
• AIRTEC CAD designed cast end tanks for improved airflow and unbeatable strength
• Reduced charge temps
• Designed to fit both DCT and manual gearbox models
• 3-year unlimited mileage warranty
• Available in Pro-Series black finish
• AIRTEC logo available at no extra charge
• Unbeatable value for money!

Choose from plain black, or add your choice of coloured AIRTEC logo free of charge.

Please note: Only available in Pro-Series black.

Registered Design Right number: Pending

AIRTEC part no: ATINTHYU3

TECHNICAL DATA

As part of our expanding Hyundai product range, AIRTEC Motorsport is proud to launch our intercooler upgrade for the i30N (2017-2021) suitable for track or fast road use.

In order to ensure there is no noticeable loss in performance during extended periods of hard driving, we have developed a larger, freer-flowing intercooler that is a direct replacement for the smaller and more restrictive OEM item.

Our solution to increasing the intercooler’s size and performance within the confines of the limited space behind the bumper is based upon a stepped twin-core design l with increased depth. This offers an increase in overall capacity in comparison to the original intercooler, as well as a substantial increase in frontal area over standard, which allows it to make the most of the air flow provided.

Together with our high-flow, moulded one-piece cast end tanks to ensure flow is directed correctly and efficiently, the AIRTEC Motorsport intercooler offers much greater efficiency and volume over standard.

With a 70mm cold side, this makes the AIRTEC Motorsport intercooler the largest on the market currently for the Hyundai i30N!

Despite this improvement, it fits neatly behind the original bumper, requires no trimming or cutting. The comprehensive fitting kit includes all the correct fixtures and fittings, step-by-step instructions with pictures, new Pro Hoses silicone hoses and should take around 2-3 hours to complete.

The intercooler is available in Pro-Series Black finish and either with or without the AIRTEC Motorsport logo and gloss black Pro silicone hoses.

Intercooler test data:

Features:

• Stepped intercooler design for maximum flow
• Designed and manufactured in the UK by AIRTEC
• AIRTEC CAD designed cast end tanks for improved airflow and unbeatable strength
• Reduced charge temps
• 3-year unlimited mileage warranty
• Available in Pro-Series black finish
• AIRTEC logo available at no extra charge
• Unbeatable value for money!

Choose from plain black, or add your choice of coloured AIRTEC logo free of charge.

Please note: Only available in Pro-Series black.

Registered Design Right number: Pending

AIRTEC part no: ATINTHYU1