Revo Intercooler Kit For Audi B9 S4/S5/SQ5 3.0T

Only The Driven know that the cooler the air, the more power produced. Revo Intercoolers drastically improve your vehicle's ability to cool the air compressed by the turbo. Increased volume and surface area, bar and plate cores with end tanks specifically designed to promote even airflow all play a part in lowering temperatures; without negatively affecting pressure.

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, even under normal driving conditions. The Revo Intercooler has been designed to improve on the stock part in every area. Restrictive elements of the stock cooler have been enhanced and cooling efficiency has greatly improved by utilising four different fin types throughout the core, increasing core volume by 90% and overall surface area by an impressive 140%.

INCREASED CORE VOLUME

The Revo Intercooler was built around a simple principle; create a cooler that can keep up with your demand for power. Designed from the ground up, the Revo Intercooler has a much larger core volume than the OEM part and offers perfect fitment, improving cooling by utilising the full volume of the available space as well as cold ambient air from the front of the vehicle.

BAR AND PLATE CORE

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.

FIN DESIGN

The new bar and plate core design now utilise a four-fin configuration designed to control charge and ambient air separately. This unique fin design significantly increases cooling capacity by up to 25% over a two-fin configuration. The ambient core side utilises louvred fins to slow ambient airflow to improve heat transfer, while the charge core side features an offset internal fin design to balance surface area and air resistance, minimising pressure drop.

END TANK DESIGN

The Revo end tank geometry maintains the largest possible cross-sectional flow area to and from the core. Coupled with a cast interior surface finish, the Revo end tanks allow air to flow freely without restriction. 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 of both key features.

BRACKETS

To ensure precision fitment, only Revo offers precision laser cut upper and lower brackets to fit integrated mounting points cast into the intercooler. As the cooler has a much larger surface area, upper brackets were essential to prevent any rotating movement.

RESEARCH AND DEVELOPMENT 

The Revo intercooler minimises turbulence while maximising heat transfer, promotes cooler air temperatures and minimises pressure drop. This helps retain 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 Stage 1 software, a Revo intake system, but otherwise stock vehicle, the Revo Intercooler was then installed and tested in the same controlled environment to highlight the benefits of enhanced cooling.

PERFORMANCE 

Four back-to-back runs were performed to gauge the various metrics of both intercoolers, as well as to see how both intercoolers responded to heat soak. With max gains of +9 HP & +25NM 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 the 4 runs.

INLET TEMPERATURE

Inlet temperature readings are used to monitor the temperature of the air going into the intercooler. This ensures controlled testing when comparing results of outlet temperatures. As highlighted in the graphs, the inlet temperatures during the Revo Intercooler test were higher (up to 27°C higher peak, an average of 8.75°C higher overall four tests), than in the test of the stock cooler, the Revo intercooler was still able to lower outlet temperatures more than the OEM part.

OUTLET TEMPERATURE

This is the main graph that illustrates the increased cooling performance of the Revo intercooler vs OEM intercooler over all four runs. The Revo Intercooler was easily able to perform over the four dyno runs with absolutely no loss in power/torque. The maximum difference between the OEM and Revo cooler in terms of temperatures was a huge 47ºC.

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 a massive core size difference there is only a 0.03psi pressure drop in comparison to the stock intercooler, ensuring engine response and minimised turbo lag. You can, therefore, rest assured that your vehicle will drive and respond as you would expect with a standard cooler, but with the improved cooling allowing you to run harder for longer.

Features:

• Unique core design with four fin types
• Fully Cast End Tanks
• OEM Direct Fitment
• 140% Increase in Surface area
• 90% Increased Core Volume