Performance - RS3 8V

Freshly developed at AIRTEC HQ in the UK, we’re proud to launch our Stage 3 front mount intercooler kit with integrated crash bar design (replaces the stock crash bar) aimed at modified Audi RS3 8V owners who want the very highest level of cooling efficiency, power and performance for track or fast road use. AIRTEC part no: ATINTVAG41 TECHNICAL DATA Freshly developed at AIRTEC HQ in the UK, we’re proud to launch our Stage 3 front mount intercooler kit with integrated crash bar design (replaces the stock crash bar) aimed at modified Audi RS3 8V owners who want the very highest level of cooling efficiency, power and performance for track or fast road use. The finished design features 70mm inlet and outlets that flow freely through custom end tanks into a stepped 100mm to 50mm single-pass core. By integrating the crash bar into the design, the intercooler makes full use of the vehicle’s entire front grille area while still retaining the towing eye feature. It therefore offers a huge 125% increase in surface area and a 108% increase in volume over standard with radically reduces charge temperatures, which is suited for highly modified examples with higher boost pressures and capable of supporting over 500bhp. It fits neatly behind the original bumper and the comprehensive kit includes AIRTEC Motorsport’s replacement bonnet catch, laser-cut brackets and all fixtures and fittings. Its proven cooling efficiency makes it an essential modification for all modified Audi RS3 8S.   Dimensions:OEM intercooler:Width: 640mm Height: 163mm Depth: 80mm Capacity: 8.3 litres Front area: 1,043cm²   AIRTEC Motorsport intercooler:Width: 627mm Height: 375mm Depth: 100mm to 50mm stepped core Capacity: 17.3 litres Front area: 2,351cm²   Features: 108% bigger capacity 125% larger frontal area Proven race quality bar and plate core 70mm inlet and outlets CAD designed end tanks to optimise air flow Comes complete with full fitting instructions Proven power increases and cooling efficiency Towing eye feature retained New bonnet catch supplied Available in Pro Series Black only   Registered Design Right number: 6171871 AIRTEC part no: ATINTVAG41

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If your car is fitted with adaptive cruise control, we can additionally supply you with a billet bracket and fixings to enable the relocation of the ACC radar. Simply select the ACC option in the drop down menu above. No re-coding of the unit should be necessary. Following on from our very successful intercooler for the RS3 8P chassis, the Forge intercooler for the RS3 8V 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 older 8P, 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 RS3 8V core is a huge 640x250x100 and of bar and plate design. This gives it a huge 55% more surface area than stock, and an even more impressive 94% more 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 8P chassis, we supply a genuine Audi RS3 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 deg C), then do 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 standard car we tested on, it made 362bhp completely stock (so largely in line with what Audi quote) with a peak intake temperature of 58°C. With just this intercooler fitted and no other modifications, the same car made 386bhp with a peak inlet temperature of 23°C, a gain of 24bhp and a drop of 35°C. Gains on mapped cars will likely be even more impressive as the stock intercooler core really starts to struggle on stage 1 mapped cars. The kit contains full instructions for installation, which should take around 3.5 hours, and a complete kit which includes everything needed. Click here to find out about information and care for yourForge Motorsport cooling product. The above dyno graph shows a Forge customer making gains of 52HP with this intercooler  5 / 5 stars - “In short, this product does what it states!” Working with Litchfield and their Technical Partners (Forge) I have conducted extensive testing to support the development of Litchfield tuning packages for the Audi RS3 8V. Whilst the OEM intercooler is “OK”, very rapidly on repeated road and dyno Wide Open Throttle (WOT) sweeps, the air charge temps quickly rise to levels that impact performance (pulling ignition). To extract the full potential out of the tuning packages and increase repeatability of results and improve overall reliability, I turned to Forge and their upgraded front mount intercooler. Not one for just using a product because of “sales speak”, I extensively tested the Forge offering. The conclusion based on the data logging, mapping and final results was clear. Monitoring charge temps with back to back tests instantly showed us that the cooling efficiency with the Forge product was significantly better. Comparing OEM intercooler charge temps for the coolest first run, against the Forge intercooler on it’s third repeated back to back run (really pushing this comparison with heat soak), the Forge intercooler saw a drop of 18degs peak over the OEM unit (on it’s coolest run with no heat soak). Repeated runs on the OEM intercooler saw the difference widen even more by up to 34degs higher (peak) than the Forge intercooler. Repeated runs between the OEM and Forge intercooler (all completed on the same day) saw the following peak values: OEM - 60degs Forge - 26degs The Forge intercooler also held the lowest charge temperature for longer. This sounds all fine and dandy but what does all this mean in relation to performance? First off Litchfield was able to develop their ECU calibrations without needing to worry about charge temperatures impacting performance. The car spent many hours on the dyno and completed many back to back runs. Over 30 different calibrations were created and tested. Not once did Litchfield need to let the car cool down between runs. The end result was a solid and repeatable 450+bhp achieved with only their ECU calibration, Forge Intercooler and secondary cat removal. Recently (March 2017), the car at this level of modification (Litchfield Stage 2) achieved a stonking 11.5s @ 118+mph quarter mile run at Santa Pod. This is the quickest time that we are aware of in the UK, for an RS3 8V at this level of modification using normal pump fuel, no weight reduction and on stock tyres. The car also achieved the 60mph sprint in 3.2s, the 100mph sprint in 7.9s and 100-200kmh sprint in 8.9s on this same run. I look forward to seeing how the Forge intercooler will complement Stage 3 development. Watch this space!   Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.

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TECHNICAL DATA AIRTEC have now released our latest intercooler for the AUDI RS3 8V. We take a huge amount of pride in making sure our kits are finished to an extremely high standard. AIRTEC Front mount Intercooler kit includes these parts & features 1 x huge 100mm core intercooler Powder coated standard intercooler support brackets No cutting to bumper Fitting instructions and all required fixings Un-Beatable value for money Proven power increases for fast road & track Available in Pro-Series Black AIRTEC 3 year unlimited mileage warranty Fitting will take 2-3 hours depending on mechanical skill Options: Option 1: Without optional crash bar – Requires existing crash bar to be cut and welded. Can be supplied with laser-cut plate and template. Option 2: With crash bar – New crash bar comes powder coated and pre-cut ready to fit – (Please add £354) Capacity intercooler – 7.97 Litres PLEASE NOTE: This intercooler will NOT fit cars with adaptive cruise control. Silver for illustration purposes only. Registered Design Right number: 6022631 Approximate dimensions: W100 mm/L650mm/H250 mm AIRTEC part number: ATINTVAG18

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REVO INTERCOOLER AUDI RS3 8V2 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 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. 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 38ºC vs. the Stock intercooler, allowing you to drive harder, for longer. KEY FEATURES Bar & Plate Core Design Fully Cast End Tanks Reinforced Mounting Brackets Intercooler Pipes Included Up to 53% increase in the frontal surface area Up to 38% increase in core volume Fits with OEM Crash Bar   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 38% larger core volume than the OEM part and offers perfect fitment by Utilising the volume of unused engine bay space behind the OEM (US and ROW) crash bar. INCREASED FRONTAL AREA Due to the custom-designed end tanks, the frontal area of the intercooler has been increased by a massive 53%. 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. 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 an upgraded aluminium charge and silicone throttle pipes. The increased diameter pipework ensures the maximum performance by increasing system volume by over 27%. The internal diameter of each silicone is precisely matched to the outer diameter of the ribbed inlet and outlet connections along with a 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, a Revo carbon series air intake system and Milltek downpipe exhaust, 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 four consecutive dyno runs, the efficiency of the Revo Intercooler over the OEM RS3 intercooler is highlighted. With peak gains of +17 HP (hubs) & +43NM Torque, along with increased performance throughout the entire rev range. The stock intercooler struggles to effectively function in comparison to the Revo Intercooler which remained consistent throughout. INLET TEMPERATURE This is a metric used to confirm that testing on the RS3 8v.2 2.5TFSI 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. As can be seen, the “dwell” between testing runs is higher with the OE setup vs. Revo. While this initially seems less than desirable for comparable data, this temperature difference is actually down to the thermal mass differences between setups; indicating 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 intake temperature-related issues arose. The graph illustrates the increased cooling performance of the Revo intercooler vs RS3 intercooler over all four runs. The Revo Intercooler provided a massive 38.2°C max and 18.23°C average intake air temperature reduction across the six back to back full gear dyno runs. 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 massive core size difference there is only a 0.34psi pressure drop in comparison to the stock intercooler, ensuring engine response and minimised turbo lag     FITMENT VEHICLE APPLICATIONS Manufacturer Model Engine Year Audi RS3 2.5TFSI 2017 onwards Audi RS3 2.5TFSI GPF 2019 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. © Revo

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