REVO | AUDI B9 A4 A5 ALLROAD 2.0 TFSI | INTERCOOLER
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%.
- Unique Core design with 4 fin types
- Fully Cast End Tanks
- 140% Increase in Surface area
- Up to 90% Increased Core Volume
- Revo Intercooler
- Revo Fitting Kit
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 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, 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.
The new bar and plate core design now utilises 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 air flow 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.
To ensure precision fitment, only Revo offers precision laser cut upper and lower brackets to fit integrated mounting points cast in to the intercooler. As the cooler has a much larger surface area, the upper brackets are 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 of 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 2 software, a stock intake system, Revo intercooler pipes and a prototype Revo downpipe, the Revo Intercooler was then installed and tested in the same controlled environment to highlight the benefits of enhanced cooling.
Three 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 +56 HP & +60NM 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 3 runs, compared to stock cooler which lost 5%.
Inlet temperature readings are used to monitor the temperature of air going in to 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 than in the test of the stock cooler, the Revo intercooler was still able to lower outlet temperatures more than the OEM part.
This graph illustrates the increased cooling performance of the Revo intercooler vs OEM intercooler over all three runs. The Revo Intercooler keeps temperatures below 45ºC on all runs compared to 90 ºC with the stock cooler. The maximum difference in temperatures was a huge 61 ºC.