Integrated Engineering FDS Intercooler – Audi A3, S3 8V 8Y/VW Golf Inc GTI, R Mk7 Mk8

FDS (FLOW DISTRIBUTION SYSTEM)

The IE FDS (Flow Distribution System) has proven to distribute charge air uniformly across the inlet end of the core. In contrast to other intercoolers on the market which rely on natural airflow across the core, our FDS technology uses precisely shaped and placed fins cast into the intake plenum to fully take advantage of the large core volume effectively using the entire core. As a result, the IE FDS intercooler has been proven to reduce intake air temperatures more so than other units available, thus offering the largest power gains possible.

TECHNICAL FEATURES

When you begin modifying your VW MK7/Audi MK3 Golf R, GTI, A3, or S3 it will become necessary to upgrade the intercooler. Once upgrades such as ECU tuning, exhaust systems, and turbo upgrades are introduced, intake air temperatures begin to rise, resulting in massive power loss. The IE front-mount intercooler system was designed to directly replace the factory unit while utilizing a much larger core and our proven FDS (Flow Distribution System) to effectively utilize that larger core. These features allow for much higher cooling efficiency than the factory system, thus reducing intake air temperatures and safely increasing horsepower output. The IE FDS intercooler is also a direct fit, requiring no cutting, modification, or time-wasting hassle during installation. Read below for more in-depth information on each intercooler feature.

ELIMINATE HEAT SOAK

Heat soak occurs when the heat generated exceeds the cooling capacity of the intercooler. The most common symptom is the noticeable loss of power after long term acceleration or several back-to-back power pulls. By greatly increasing the core size and useable area of the core with FDS technology, we have eliminated the heat soak, keeping the intake air temperatures consistently lower than OEM and competition intercoolers.

PRECISION-ENGINEERED

Unlike other intercoolers that are simply put together to fit on the car and offer a larger core, the IE FDS intercooler line receives special treatment from start to finish. Our engineering department used Computational Fluid Dynamics (CFD) software to optimize the end tanks and FDS system for minimum pressure drop and maximum flow. Once the end tanks have been designed and flow has been optimized, the 3D models head over to our 3D printing studio to manufacture the initial prototype.

The 3D printed end tanks fastened onto a production core for testing. To validate the FDS technology, we test each model of the intercooler in a controlled environment on our in-house engine dyno. A total of 16 temperature probes are placed on the core, with a column of 8 on either side. This allows us to collect data at multiple points on the inlet side and outlet side of the intercooler to verify temperature distribution across the core. Once that data has been collected, it is analyzed and used to determine if changes in location or pitch of FDS channels are necessary before going to production.

DECREASED PRESSURE DROP

Along with lower intake air temperatures, the large core within the IE intercooler also decreases pressure drop when compared to the factory unit. Simply put, a pressure drop is the amount of pressure that is lost as air travels through the intercooler. As boost pressure is raised, pressure drop typically begins to climb. By using a larger core that flows much more freely than the factory core, the pressure drop is reduced, reducing the need for the turbocharger to work harder to produce the required boost levels.

HIGH-QUALITY CONSTRUCTION, PERFECT FITMENT

Not only does it offer the highest cooling efficiency on the market, but the IE FDS intercooler also offers perfect OEM replacement and requires no modifications to install.   Many other kits available require cutting and drilling for fitment, which is the last thing you want to do to your MK7. With CNC machined mount points, each and every IE intercooler allows you to reuse the factory mounting points and installs as if it were a factory piece.   You will also find that the IE intercooler receives the same attention to detail and quality as every other IE product, with U.S cast and machined end tanks, precise TIG welding, and a dense bar-and-plate core. Every intercooler is tested on our in-house intercooler testing station before shipping, ensuring that it is ready to install.

COMPLETE KIT 

The IE MK7 intercooler comes complete with high quality, 4-ply reinforced silicone hoses, which allow connection directly to the factory outlet and throttle pipes. We also include every piece of hardware needed for installation.

INSTALLATION PROCESS

Installation is straightforward with basic tools but may include a few more technical steps and draining of coolant. The process should take around 3-4 hours hour for an experienced technician, and possibly longer for the automotive enthusiasts. We recommend you familiarize yourself with the installation process before attempting. CLICK HERE to view and download Install Guide.