Why: -Well the intercooler is a key part of the forced induction system on a turbocharged engine. The way I understand it is an intercooler will decrease the air intake temperatures to provide a denser intake charge to the engine and allows more air and fuel to be combusted per engine cycle, increasing the output of the engine. As it keeps intake temperatures down it will also help prevent heat soak degrading engine performance when pushing on.
So like anything on the car once you step on the slippery slope of modifying the stock components will soon become stretched beyond their normal duty cycle.
Since going to Revo Stage 2 I had started to see some high intake temperatures (over 30c above ambient for example on a Rolling Road session).
So I thought it was time to invest in a new IC. Initially I was planning to go the S3 route but after seeing a test version of the THS intercooler on Revo's Leon K1 and from speaking with Carl and Martin @ Revo I thought it made more sense to try the THS intercooler.
Here are some side by side pictures of the new THS cooler and the old stock IC
Here's the blurb on the IC from THS: -
And a comparision on size with the stock and S3 IC's
Sourcing: -The intercooler is supplied directly by THS Performance: -
Website -
www.thsperformance.co.ukEmail - sales@thsperformance.co.uk
Installation: -Installation isn't a task for the faint hearted
As you can see all of the front end parts need to be removed to gain access to the stock IC.
I had mine installed by Neil and Ollie from THS as they are finishing the write-up for the installation manual so offered to do it as part of the purchase price
Generally the installation was pretty painless (apart from when Ollie stabbed Neil with a a screwdriver in his arm where he had burnt it earlier that week
).
In total it took just over 3 hours which considering we where taking photo's of every step wasn't too bad.
Here are some more installation photo's
Once the physical installation was complete we took the car out for some post installation logging with VCDS connected.
Immediately the intake temps were well down on the old stock IC and showed better recovery of temperature after a few spirited runs
I will be completing some more logging over the next few days so will post some more detailed results as soon as I can
Plus Points: -- Direct Replacement for the Stock IC
- All Alloy construction designed with the best possible air flow in mind
- Improved performance and reduced intake temperatures
Minus Points: -Really none that I can think of really
Summary: -After having run the car for a few days/nearly 1000 miles on the IC (during the hottest days of the year so far!) I can really say I have been massively impressed with the difference this is making to the car.
It is really noticeable in the mid to top end power the car really pulls so much more now and despite my best efforts I am not feeling the effects of heat soak as much as I did before.
Everything else about the car has remained as before (so no affect in fuel consumption etc).
Also I was really impressed with the way the kit was put together, previous from other manufactures I have seen simple things to make the installation easier aren't included, but the THS kit will be supplied with everything you need (for example even down to a cable tie in-case you have to cut the existing one on the bonnet release cable) and some bit like longer bolts to help temporarily support the front crash panel while removing the old IC.
So I would 100% say I would recommend this IC to any 2.0 TFSI owner as you will be really surprised at the difference it will make.
Finally thanks to Neil & Ollie from THS for doing the installation on a Sunday morning while they where local to me (and to Neil's dad for the loan of the workshop)
UPDATE
Data Logging Results: -
I have finally got around to doing some data logging with the IC installed. I tried I couple of scenarios to get an idea of how it performs in normal driving conditions.
So at the time of these tests my car is running: -
Revo Stage 2+ Code (B9 T6 F9)
KMD HPFP Kit
Milltek Turbo Back Exhaust
Test version of the VWR Direct Intake System that fits onto Standard Airbox
Test 1 - Fast Road Hard AccelerationOutside Temp 17°c
So over a 15 minute period starting with the engine up to temp I logged the car over a few 1-2 mile stretches of Dual carriageway broken up by roundabouts where I tried hard acceleration (upto the national speed limit only).
The starting intake temp (as the car was idling for 5 minutes while setting up the laptop) was 38°c.
Immediately under the initial acceleration the temp dropped by 5°c to to 33°c.
At peak the maximum temp I recorded after about the 4th run of accelerating away from a roundabout at maximum revs in 3rd was 39°c. This would immediately drop as soon as you ease off when coming up to the next roundabout.
The average temp recorded over this test was 31.5°c which is above 14.5°c ambient.
Test 2 - Recovery from Heat SoakOutside Temp 20.5°c
For this test I spent around 45 minutes in slow heavy traffic coming out of London followed by 10 minutes queuing at the petrol station for so much need V Power.
Once I started I logging the start after filling up the intake temp was showing as 58°c.
After the first 30 seconds of driving the intake temp dropped by 10°c and after a further 4 mins of driving at varying speeds between 40-70mph the intake temps had recovered back to 31-32°c or just over 10°c above ambient.
