Unitronic is proud to release its Intercooler Upgrade for the 2.5TFSI EA855 EVO engines, found in the 8V.2 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 provides a dramatic reduction in charge air temperatures to ensure peak performance is achieved and sustained while resisting heat-soak after repeated efforts and in harsh climates and conditions.

Consistent with all of its performance products, Unitronic utilizes only the latest industry leading tools, equipment and computer aided design software that are packed with the latest technology from our technology partners at Creaform and Stratasys. These tools and technology help to achieve a design that not only optimizes thermal efficiency, but airflow to maintain the least amount of pressure drop, while fitting within the space constraints without affecting the frontal crash bar assembly or other components behind the front bumper.

At Unitronic, development begins with setting the objectives; performance, efficiency, aesthetics and quality. Operations start with 3D scanning the 2.5TFSI EVO engine bay and OEM components with its in-house 3D scanner. Once 3D scan data has been collected and processed, Unitronic Hardware Engineers then interact with the 3D models to identify fitment constraints, mounting locations, other component locations, etc. to ensure the final product fits perfectly within the envelope.

Engineering begins with the evolution of the design in meeting the objectives. Criteria from a top level is first met with the platform’s structural constraints; developing it from the details in optimizing the design. With upfront engineering fluid dynamics (EFD), Unitronic is able to hone in and refine the areas that are most effective in meeting those objectives.

With the ability to perform different iterations from design changes we are also able to 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 is also able to predict the thermal exchange of the intercooler core in the wake of air passing through the channels. This provides further insight on 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 resulting in an increase in engine performance.

When intake air temperatures reach a specific threshold, the engine control unit begins to compensate to account 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.

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 front end of the vehicle. 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.

Ambient air temperature was stable at 48F (9C) throughout the day. Testing consisted of 6 consecutive dyno pulls with a 20 second pull and a 60 second cool down period in between runs, with both the OEM and Unitronic Intercoolers to collect intake air temperatures to provide data on cooling abilities, 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 reductions in air temperature 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 through the most rigorous of conditions. The graphs below show the Unitronic Intercooler performing much better than a competitor’s unit and the OEM unit as well.

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 prior to approving this Intercooler for production. Unitronic’s cast Aluminum end tanks are designed with tolerances of +/- 0.020 to ensure perfect fitment across all of our 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.

FEATURES

Highly efficient bar & plate intercooler core

Drastically reduces charge air temperature for cooler, more dense air

Significantly more resistant to heat-soak

71% more volume than OEM (Unitronic Core Dimensions: 24 x 10.25 x 3.5 / 610mm x 260mm x 90mm)

Cast Aluminum end tanks

Direct OEM replacement; no bumper, radiator support, or other trimming required

*This part is designed for North American vehicles only, but can fit an EU vehicle, when swapped to a North American from crash bar.