Focus MK4 All Models

AIRTEC Motorsport Front Mount Intercooler Upgrade for Focus ST Mk4 Developed and manufactured at AIRTEC HQ in the UK, we’re proud to launch our front mount intercooler upgrade suitable for modified Mk4 Focus ST  models for track or fast road use. AIRTEC part number: ATINTFO55 TECHNICAL DATA AIRTEC Motorsport Front Mount Intercooler Upgrade for Focus ST Mk4 Developed and manufactured at AIRTEC HQ in the UK, we’re proud to launch our front mount intercooler upgrade suitable for modified Mk4 Focus ST  models for track or fast road use. With limited space available behind the front bumper arrangement of the Mk4 Focus model, our solution to increasing the intercooler’s size and performance is based upon our stepped-core design to fully utilise the area. The core steps from 85mm to 35mm and in doing so offers a huge increase in overall capacity in comparison to the original intercooler. It also offers a significant increase in frontal area over standard, which allows it to make the very most of the air flow provided. Together with our high-flow, moulded one-piece cast end tanks and an internal air diverter to ensure flow is directed correctly and efficiently, the AIRTEC Motorsport intercooler offers much greater efficiency and volume over the standard item. Despite this huge improvement, the kit fits neatly behind the original bumper and requires only minor trimming, and can be reverted back to standard with no issues. It attaches to the original boost pipes and the kit comes complete with fittings that allow the intercooler to simply and easily attach in place using our own design of billet mountings. The comprehensive fitting kit includes all the correct fixtures and fittings, as well as step-by-step instructions. The intercooler is available in a Pro-Series Black finish and with or without the AIRTEC logo. Specification:Height – 185mm Depth – 85mm/35mm step Width – 730mm Registered Design Right number:  AIRTEC part number: ATINTFO55

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FORD FOCUS ST MK4 | INTERCOOLER Only The Driven know that the cooler the air, the more power produced. Revo Intercoolers drastically improve your vehicles ability to cool air compressed by the turbo. Increased volume and surface area, bar and plate cores with cast end tanks specifically designed to promote even air flow all play a part in lowering temperatures; without negatively affecting pressure. REVO INTERCOOLER FORD FOCUS ST MK4 2.3 ECOBOOST  The Revo Intercooler utilises unique design features to lower intake air temperatures, minimise pressure drop and allow the engine to produce impressive power and torque with Revo Software. The unique end tank profile promotes internal laminar flow by decreasing turbulence and increasing airspeed and volume into the bar and plate core. This enhances charge air cooling giving you access to more power throughout the rev range. The limitations of the stock intercooler were apparent throughout testing with space being one of the largest factors when looking to improve over the stock unit. The stock part consistently struggled to manage charge air temperatures, especially on vehicles with performance software. The Revo Intercooler has been designed to improve on every restrictive element of the stock cooler, enhancing cooling efficiency by lowering intake air temperatures by up to 33.3ºC vs the Stock intercooler, allowing you to drive harder, for longer. KEY FEATURES Bar & plate core design Fully cast end tanks 20% Increased inlet and outlet diameter Intercooler pipes Included 13% increase in the frontal surface area 28% increase in core volume Complete OEM fitment, requiering no modification OEM VS REVO When you begin to enhance performance the restrictive OEM intercooler struggles to reduce intake temperatures and flow enough air, robbing the engine of power. One of the largest restrictions we found in the OE unit was the size of the inlet and outlet of the cooler, as you increase the power of the car the charge air temperatures increase, with the increase in charge air temperatures the OE unit starts to become a choking point and increases those temperatures further due to insufficient flow. The Revo Intercooler Kit removes the most restrictive elements, increasing the inlet and outlet sizes combined with a larger core, reducing intake air temperatures and promoting smoother airflow.  INCREASED CORE VOLUME The Revo Intercooler was built around a simple principle; create a cooler that can keep up with your power demand. Designed from the ground up, the Revo Intercooler has a 28% larger core volume than the OEM part and offers perfect OE fitment with no modification to the bumpers or grill.  INCREASED FRONTAL AREA Due to the custom-designed end tanks, the frontal area of the intercooler has been increased by over 13%. Offering the best balance between increased performance and acceptable part clearance, whilst also minimising pressure drop. END TANK DESIGN The Revo end tank geometry maintains the largest possible cross-sectional flow area to and from the core. With a cast interior surface finish, the Revo end tanks allow air to flow freely without obstructions. The design has been balanced between core width and optimal tank profile design. The inlet and outlet sizes have been increased by 20% over the OE design allowing significantly more airflow and volume, reducing charge air temperatures. End tanks play an important part in maintaining pressure and work in harmony with the core to promote airflow, the Revo end tanks are designed to offer the optimal balance between both of these key features.   BAR & PLATE Designed with a bar and plate core to maximise the efficiency of heat transfer, the pressure drop is also controlled as the air meets less resistance compared to that of a tube and fin alternative. The Revo Intercooler also features carefully specified fin geometry to maximise cooling properties while minimising flow restriction. The ambient core side utilises louvred fins to slow ambient airflow which improves heat transfer, while the charge core side features an offset internal fin design to balance surface area and air resistance to minimise pressure drop.   INTERCOOLER PIPE UPGRADE Supplied with upgraded and increased sized 4 ply silicone hoses. The increased diameter silicone hoses allow for increased air volume to the cooler, reducing the heat build up the OE ones suffer at the inlet of the intercooler. The internal diameter of each silicone is precisely matched to the diameter of the Revo intercooler with unique Flush Fit design, allowing a smooth transition between components. RESEARCH AND DEVELOPMENT All Revo products are designed in-house using the latest 3D printing technology, CAD and CFD software. Every product is rigorously tested utilising an in-house Hub dyno and Revo data acquisition software. The Revo Intercooler minimises turbulence while maximising heat transfer, promoting cooler air temperatures and low-pressure drop. This helps retains power and torque throughout the rev range as highlighted during controlled Dyno testing. The Revo Intercooler was tested in-house to compare the performance against that of the stock Intercooler. First tested on a vehicle running the OEM intercooler with Revo Software and a Revo Open Cone Intake System, the Revo Intercooler and pipes were then installed and tested in the same controlled environment to highlight the benefits of enhanced cooling. PERFORMANCE DATA Showing the last of six consecutive dyno runs, the efficiency of the Revo Intercooler over the OEM Focus ST intercooler is highlighted. With peak gains of +38 HP (hubs) & +45NM Torque, along with increased performance throughout the entire rev range averaging a gain of +8HP (hubs) and +10NM Torque.  The stock intercooler struggles to effectively cool the charge air due to the tube and fin design and restriction in the intercooler inlet and outlet sizes. The Revo cooler is able to cope with the demand far better retaining power even in the harshest of conditions where the OE unit starts to fail.   INLET TEMPERATURE This is a metric used to confirm the testing on the Focus MK4 ST intercooler. This is used to show that the air temperatures going into the intercooler were similar for each test, confirming that outlet temperatures shown in the following graphs are purely down to differences in intercooler design/construction. However in the case of the Focus MK4 ST OE cooler, due to inefficiency in the OE design of the charge pipes and cooler you can see that the starting temperature is higher from Run1 through to Run6. The main cause of this is again the inlet size of the intercooler and associated pipe work, these parts cause a choking point in the stock system increasing starting temps before they have even been cooled. With the increased size and flow characteristics of the Revo Intercooler and pipes the temperatures are significantly reduced prior to being cooled, a max reduction of 88.3°C and 21.7°C average over six runs. This indicates that the Revo kit can absorb much larger amounts of heat more efficiently than the OE setup, yet the Revo Intercooler produced the lower outlet temps proving the cooling efficiency. OUTLET TEMPERATURE This is the main performance metric to illustrate that the Revo intercooler far exceeds the stock unit. A strong indication that the Revo Intercooler is extremely resistant to heat soak and could likely continue for ten more sequential dyno runs before any significant intake temperature-related issues arose. The graph illustrates the increased cooling performance of the Revo Intercooler vs Focus ST intercooler over all six runs. The Revo Intercooler provided a massive 33.2°C max and 11.1°C average intake air temperature reduction across the six back to back full gear dyno runs, and yet even by the sixth run was still cooler than the starting run on the OE intercooler.  INTERCOOLER PRESSURE DROP GRAPH Pressure drop is an important factor when it comes to choosing an intercooler. The Revo solution features custom cast end tanks to evenly distribute air over the core. This graph highlights that even with the increased core size difference there is only a 0.09psi pressure drop in comparison to the stock intercooler, ensuring crisp engine response and minimal turbo lag.     FITMENT VEHICLE APPLICATIONS Manufacturer Model Engine Year Ford Focus ST MK4 2.3 Ecoboost 2018 onwards   Notes: Simple replacement of the OEM part. Compatible with OEM Rest of World and US crash bars.  Please contact your local Revo Authorised Dealer for additional information and availability.

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TECHNICAL DATA As part of our expanding Mk4 Focus ST product range, AIRTEC Motorsport are proud to launch our secondary intercooler kit for fast road and/or track use. The challengeDue to the limited space available in the upper grille area due to the car’s intake system and ducting, it isn’t possible to fit a full-size front mount intercooler to fill the entire height of the grille without significant modification. Whilst we do offer an intercooler upgrade with a deeper core design (AIRTEC Motorsport Intercooler Upgrade for Focus ST Mk4), we still looked at other ways to improve cooling and reduce charge temperatures without having to cut or modify the car. The solutionDesigned and developed at AIRTEC HQ in the UK, our solution was to develop a secondary intercooler that mounts underneath the car behind the undertray and is fed fresh air from a duct. By adding a second intercooler in place of the pipework section after the turbo, we were able to significantly reduce the temperature of the air before it entered the primary front mount intercooler, allowing it to operate more efficiently whilst offering a huge increase in overall capacity to the whole system. Despite this huge improvement, the kit fits neatly behind the undertray and can be reverted back to standard with no issues. The comprehensive fitting kit includes Pro Hoses silicone pipes together with all the required fixtures and fittings, as well as step-by-step instructions. The testingUsing a Stage 2 tuned car, measuring intake temperatures during back-to back testing on the road over eight consecutive runs showed that with the secondary intercooler in place charge temperatures were reduced by up to 44 degrees, proving the set up worked effectively and efficiently. AVERAGE INTERCOOLER OUTLET TEMPERATURE WITHOUT 2nd Intercooler 53.1 WITH 2nd Intercooler 14.4 Difference -73% Please note: Only fits manual gearbox models. Will fit with original boost pipes and intercooler or with AIRTEC Motorsport big boost pipe kit and/or our uprated intercooler.  Dimensions:Capacity: 2.7 litresFront area: 442cm² AIRTEC Part Number: ATINTFO61

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HARDWARE WILL BE SHIPPED FOR SELF INSTALL - SOFTWARE MUST BE INSTALLED AT OUR BRADFORD HQ Enhanced power delivery, unique safety features and exhilarating response at your disposal, the Revo Performance Pack delivers much more than peak power figures. Whatever drives you, the Revo Performance Pack has it all EVERYTHING YOU NEEDFOR THE POWER YOU CRAVE Enhanced power delivery, unique safety features and exhilarating response at your disposal, the Revo Performance Pack delivers much more than peak power figures. Whatever drives you, the Revo Performance Pack has it all. Engineered to perform, only Revo offers a complete tuning solution specifically designed for your vehicle. AIR INTAKE SYSTEM PERFORMANCESOFTWARE INTERCOOLER PIPE UPGRADE KIT INTERCOOLER     OPEN CONEAIR INTAKE SYSTEM Revo Open Cone Systems completely replace the OEM air intake for those who like to announce their vehicle is far from standard. Along with an aggressive intake sound, more air means access to more power throughout the rev-range. IncreasedDiameter DirectFlow PerformanceDesigned Learn more about this product PERFORMANCE ECU SOFTWARE Revo performance Software is designed to safely enhance the driveability of your vehicle, giving access to more power and torque throughout the rev range while maintaining the extensive factory safety mechanisms. Revo Software offers a perfect balance of performance, economy, longevity, and safety so you can drive harder, for longer. OBDII PortInstalled Vehicle HealthCheck Authorised DealerSet-up Read More     INTERCOOLER PIPE UPGRADE As well as the Intercooler, the Revo Performance Pack also includes the Intercooler pipe upgrade.  It reduces charge system resistance and improves flow over the restrictive stock pipework. Featuring fewer restrictions for smoother airflow, and optimised routing, the turbo meets less resistance and can perform more effectively. DirectReplacement IncreasedDiameter DirectInternals INTERCOOLER UPGRADE The Revo Intercooler was built around a simple principle; create a cooler that can keep up with your demand for power. Unique design features lower intake air temperatures, minimise pressure drop and allow the engine to produce impressive power and torque with Revo Software, ensuring you get consistent performance when you need it most. DirectReplacement UniqueFin Design MinimisedPressure Drop Learn more about this product     STOCK POWER280PS TORQUE410NM POWER410PS TORQUE590NM Find your nearest Revo Authorised Dealer Manufacturer Model Variant Engine Year Ford Focus MK4 ST 2.3 EcoBoost 2018-2022 Ford Focus MK4.5 ST 2.3 Ecoboost 2022 > Images shown are for illustration purposes only All Revo Software availability is ECU ID dependant. Upgrade pricing for existing Revo Stage 1 ECU customers.  Terms and Conditions apply.  Performance data is taken from 2019 MK4 Ford Focus ST. Pricing does not include the installation of parts, please contact your local Revo Authorised Dealer.

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