APR Front Mount Intercooler For 2.0T FSI/TSI

Brand Description:

USP Motorsports is proud to offer products from the global leader in performance aftermarket products, APR. APR develops and manufactures hardware, software, calibration & data-logging tools for engine and transmission controllers, including intakes, exhaust systems, intercoolers, turbocharger systems, suspension, brake systems, wheels, and more.

Product Description:

The APR Intercooler System dramatically lowers charge air temperature and resists heat soak far better the factory intercooler system. Through a massively increased core volume, superior intercooler core design and smooth, cast end tanks, APR's engineers were able to create an intercooler capable of supporting power levels well beyond that of the factory unit. Expect increased horsepower and torque and dramatically prolonged performance.

  Features:

-- Cast Aluminum End Tanks

-- Bar and Plate Core Design

-- Silicone Pressure Hoses

-- Direct OEM Fitment - NO Trimming Necessary

-- Fits ANY Stock or Aftermarket Bumper Cover

-- Adaptor Coupler for Stock Plumbing

The Concept:

APR’s Intercooler Kit for the transversely mounted 2.0T FSI was designed with maximum performance and minimal intrusion in mind. APR’s unique ability to design and cast intricate aluminum end tanks allows us to make an intercooler that fits in the same location as stock, but with a much larger core size.

When moving this air to and from the intercooler, you want to do so with the least amount of resistance as possible. With this in mind, plumbing was designed for the intercooler. Silicone tubing was used to create seamless internal geometry for the air to flow through while also allowing smooth transitions between diameters. A unique CNC-machined coupler allows the silicone APR hoses to connect to the rest of the stock inlet plumbing.

Overall APR’s FMIC kit is the absolute best kit you will find on the market today. We work hard to design, engineer, and test products that will last long and perform well for years to come and this product is no exception.

Several tests were done in order to prove the differences between the stock intercooler and the APR one. One test for thermal effectiveness involved placing the car on the dyno with our normal assortment and arrangement of cooling fans. The car was then run through a rigorous testing procedure that involved allowing it to idle to a normal operating temperature, and then running it through five power runs.

Intake Air Temperature Testing
Click to enlarge

During each run, the engine speed was brought to 2000 rpm for fifteen seconds. This allows the air to run throughout the system and allows the intake air temperature to normalize and negate heat soak from the car sitting at idle. The car was then taken from 2000rpm to 6800rpm at full throttle under load over the next thirty seconds. The car was then allowed to idle for one minute before the next run was started. Each lighter line on the graph above represents each power run, and the darker line represents the average over five runs.
The stock intercooler was tested on one day, the APR intercooler was installed, and the testing repeated the next day. The conditions were very similar on both days, however it was slightly hotter (3ºF) on the day the APR intercooler was tested.
Most alarming about this entire test was the fact that during the third run with the stock intercooler, the car began to pull boost and timing in order to protect itself from the high intake temperatures. The car also exhibited this protective behavior in both the fourth and fifth runs as well.
The APR intercooler performed as we expected, keeping the intake charge temps almost 40ºF lower by the end of the fifth run. Given the fact that no dynamometer test cell can reproduce the airflow that a car on the open road gets, we are confident that differences between the APR intercooler and the stock one would be even more apparent on the street or track.
During the testing on the dyno, a normal dyno power run was performed with each intercooler, and the APR intercooler recovered upwards of fifteen horsepower over the stock intercooler. The uncorrected, wheel horsepower is displayed in the graph below.

Dyno Testing (Uncorrected Wheel Horsepower)
Click to enlarge

APR FMIC Component Highlights

End Tanks
APR all aluminum end-tanks are factory like cast pieces. A cast piece ensures consistency in the production process, which in turn guarantees proper fitment to the core. Once mated and welded to the core, all assemblies are pressure tested to 60psi. This intricate end tank design allows the APR intercooler to fit in the factory location with the stock air conditioning condensor and radiator bolted to it. No sheet metal endtanks here... You won't find this attention to detail in any other offering.

Intercooler Core

There are two primary core designs commonly used for cooling: the bar and plate design and the extruded tube. While both offer similar performance, a bar and plate intercooler is more efficent for cooling the intake charge temparature.
The size of the core is also very important. The APR intercooler for the Transverse 2.0T FSI is a massive 16.25" tall, 2.25" thick, and 23.2" wide. From a standard chipped car to a Stage III, this core is extremely efficient and does an outstanding job in reducing intake temps.

Silicone connectors
The tooling for the silicon hoses is drawn up on Pro-Engineer and manufactured in house for precise fitment. Incorporated into the design is a recessed end, which allows the pipe to lie flush inside the hose, eliminating protruding edges that inhibit airflow.

Adapter coupler
The APR intercooler includes a specially designed and CNC-machined annodized aluminum coupler that allows the APR silicone intercooler hoses to connect to the original equipment connections just like the factory rubber lines. This design allows a quick-disconnects while maintaining a solid, leak-free connection.
 

*The APR Intercooler core will fit the Audi TT with the new 2.0 TFSI Audi Valve Lift engine, but requires the Spulen Discharge Pipe:  SE-01301 and 1K0 145 769 J 

Due to our dealer agreement, APR products cannot be shipped outside of the United States.