Unitronic® is proud to release its Intercooler Upgrade for the 2.5TFSI EA855 EVO engines found in the 8V.2 and 8Y Audi RS 3® and 8S Audi TT RS®. This direct OEM replacement bar and plate intercooler is available with a black or raw finish and dramatically reduces charge air temperatures to ensure peak performance is achieved and sustained while resisting heat soak after repeated efforts and in harsh climates and conditions.

With the ability to perform different iterations from design changes, we can also accurately predict how well it will perform. Below is a predictive simulation plot operating within the same conditions it was tested in. Results illustrate and validate the actual data collected. Using EFD simulations, Unitronic can also predict the thermal exchange of the intercooler core in the wake of air passing through the channels. This provides further insight into how our design will impact engine cooling and HVAC efficiency.

Unitronic's bar and plate intercooler core features a unique staggered and louvered fin configuration to maximize efficiency, significantly reducing charge air temperatures allowing for cooler, more dense air to be inducted by the engine, ultimately increasing engine performance.

When intake air temperatures reach a specific threshold, the engine control unit begins to compensate for the air temperature, resulting in a decrease in performance. Unitronic's core measures 24” x 10.2” x 3.54” (610mm x 260mm x 90mm), a 71% increase in volume over stock, allowing for a greater volume of air to exchange heat, which, combined with a proper fin configuration, allows for maximum efficiency and reduction in heat-soak thresholds without producing a significant pressure drop.

Testing:

Utilizing its own 8S Audi TT RS for research and development provided Unitronic with an in-house platform to run through testing. Data was collected on its in-house MAHA Chassis Dynamometer, using our standard cooling fans with ducting properly aligned with the vehicle's front end. The vehicle's front bumper/fascia was fully affixed for all tests. All data was collected on the same day, starting with the OEM intercooler testing first.

The ambient air temperature was stable at 48°F (9°C) throughout the day. Testing consisted of 6 consecutive dyno pulls with a 20-second pull and a 60 second cool down period between runs, with both the OEM and Unitronic Intercoolers to collect intake air temperatures to provide data on cooling abilities and efficiency and resistance to heat soak compared to the OEM unit.

The graph above shows the Intake Air Temperature for both the OEM and Unitronic Intercoolers, individually for each of the 6 runs. The Unitronic Intercooler provided significant air temperature reductions resulting in a cooler, denser charge air being ingested by the engine, resulting in increased performance. Its resistance to heat soak means that the core retains its cooling abilities, even though the most rigorous of conditions. The graphs below show the Unitronic Intercooler performing much better than a competitor's unit and the OEM unit.

Entering and exiting the core is an important aspect that should not be forgotten about. With airflow and fitment implications, Unitronic went through many end tank prototypes and production samples before approving this Intercooler for production. Unitronic's cast Aluminum end tanks are designed with tolerances of +/- 0.020” to ensure perfect fitment across all production units. Inlet and outlet design has also been optimized to ensure smooth airflow through the intercooler and features barbed/serrated bead rolled machining to ensure the charge hoses stay securely affixed.