AWE Tuning Audi S4 Sedan 2.7L Turbo Performance Intercooler Kit - With Carbon Fiber Shrouds 4510-11040

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AWE Tuning Audi 2.7T Performance Intercooler Kit - With Carbon Fiber Shrouds

Group AWE_2.7T_Intercooler_Kit Description

Presenting the AWE Tuning Audi 2.7T Performance Intercooler Kit. Cast End Tanks. Carbon Fiber Shrouds. Backed by AWE Tuning R&D. If you're serious about consistent and proven power, read on.

Why we developed this kit

The stock 2.7T intercoolers become a power handicap at high boost levels, which is not surprising considering that the stock 2.7T boost level is just 8-9 psi. Every performance software on the market, let alone an upgraded turbo kit, runs almost double this boost level. This results in tangible power losses, especially when outside temperatures rise.

When investigating intercoolers, ask for data that demonstrates how the kit will perform at 20psi boost levels, which is the norm for most current 2.7T turbo kits. If you are running less boost than this, then you can rest assured that there is sufficient headroom in the design should you decide to upgrade turbos one day.

About the AWE Tuning Audi 2.7T Performance Intercooler Kit

The tested AWE Tuning Audi 2.7T Performance Intercooler Kit design uses a closely stacked bar and plate type core, to minimize pressure drops while maximizing heat transfer. Our design target was to exceed the cooling and flow capabilities of Audi RS4 intercoolers - and through this proven design, we have accomplished this (See detailed test results in the Performance Specs tab). In summary, the AWE Tuning Audi 2.7T Performance Intercooler equals the RS4 intercooler flow rates, and definitively conquers the RS4 intercooler temperature drops.

Tested. Hard.

The construction of the AWE Tuning Audi 2.7T Performance Intercooler Kit is of the highest quality - Efficient cast end tanks are used to ensure maximum flow, and each intercooler assembly is pressure checked before it leaves our manufacturing facility. And in 2012, AWE Tuning introduced carbon fiber shrouds to the mix, producing a lighter, and more aesthetically appealing kit as well.

The bulk of our side mount intercooler testing was conducted on S4s with the AWE Tuning RSK04 kit installed. This is important to consider, given that as boost rises, so will boost drop due to core restriction. Thus, an intercooler can perform well at relatively low boost levels, but can begin to perform worse than stock if the boost drop is high enough to negate any gains seen from temperature drops.

Fitment

Not only did we want the AWE Tuning Audi 2.7T Performance Intercooler Kit to be clearly superior to the RS4 unit performance, but we also wanted to take the opportunity to design a kit that required very little modification to the US spec Audi 2.7T models during fitment. The RS4 intercooler units are made to fit the Europe only RS4, and mating them to a US spec 2.7T model requires significant cutting of both the intercoolers and the vehicle itself. Our design can be fitted in less than half the time of the typical RS4 kit. This means paying less for labor charges.

Since RS4 units were never intended to be used on the US S4 chassis, extensive modifying or tweaking of the areas around the intercoolers is needed to force fitment. The AWE Tuning Audi 2.7T Performance Intercooler Kit was designed and built to fit the US S4 chassis, resulting in a much better, cleaner fit with very little modification required.

Some key fitment detail differences between the AWE Tuning Audi 2.7T Performance Intercooler Kit and the RS4 kits:

• 100% coverage of the core face with AWE Tuning Carbon Fiber air ducts. RS4 kits leave gaps around face that lets cooling air escape
• No modification needed to the engine belly tray with our design
• Cores are secure and supported
• No modification or cutting of bumper required

Options

The AWE Tuning Audi 2.7T Performance Intercooler Kit comes complete with two AWE Tuning Performance Intercoolers, AWE Tuning carbon fiber shrouds (air ducts) and a detailed installation manual. No specialty tools are required for install.

The AWE Tuning carbon fiber shrouds are also available independently, should you already have the AWE Tuning Audi 2.7T Performance Intercooler Set and like to upgrade your shrouds to carbon fiber.

Please note, the AWE Tuning Audi 2.7T Performance Intercooler Kit is for racing use only.

** NOTE: In order to fit A6 or Allroad models, minimal trimming of the bumper and shrouds is necessary.

Search Terms: 4510-11040, 4510-11042

• By AWE Tuning
• Maximum side mount dimensions
• AWE Tuning designed carbon fiber shrouds
• Extremely efficient air to air design
• Perfect Fitment - Guaranteed

AWE Tuning Audi 2.7T Performance Intercooler Dyno Test Results

Below are comparison dyno tests, as performed on the AWE Tuning Mustang MD-500-SE AWD dyno.

AWE Tuning Audi 2.7T Performance Intercooler Kit vs stock intercoolers

(Above) Dyno comparison of stock vs AWE Tuning Audi 2.7T Performance Intercooler Kit. Power is to the wheels (multiply by 1.28 for crank power). AWE Tuning Audi 2.7T Performance Intercooler Kit horsepower is green line, AWE Tuning Audi 2.7T Performance Intercooler Kit torque is blue line.

(Above) Graph of measured differences between baseline and test in dyno sheet of AWE Tuning Audi 2.7T Performance Intercooler Kit vs. Stock. AWE Tuning Audi 2.7T Performance Intercooler Kit produced a peak increase of 18.5 ftlbs and an increase of 19.5 hp to the wheels vs. the stock intercoolers. Notice, however, that at ~3500 rpms, AWE Tuning Audi 2.7T Performance Intercooler Kit produced a 24 ftlbs increase, and at 6500 rpms a 22 hp increase. That's ~31 ftlbs and 28hp gains at the crank!

Intercooler Pressure Drop Test Results

Tests were conducted on the AWE Tuning Mustang MD-AWD-500-SE AWD dynamometer, using its integrated boost pressure sensor and data acquisition. Several boost pressure measurements were taken before and after each of the intercooler assemblies and averaged, with a graph of their deltas shown above. Our RSK04 turbo kit will produce boost pressures of ~20psi through most of the rpm range.

Note that the RS4 and AWE Tuning Audi 2.7T Performance Intercooler Kit pressure drops (amount of pressure lost through the intercooler due to flow restrictions) are nearly identical to each other, at approximately 1.00 psi max. However, the stock 2.7T intercoolers become quite restrictive at high boost levels, resulting in approximately a 2.50 psi restriction to the turbos.

The lower the pressure drop, the less the turbos have to work to meet the chip's boost demand, ultimately resulting in less intake heat.

Intercooler Temperature Drop Test Results

Tests were conducted on our Mustang MD-AWD-500-SE AWD dynamometer, using dual Omega DPi temperature meters and the dyno's integrated data acquisition. Several dyno runs were made recording temperatures before and after each of the intercooler assemblies and then averaged, with a graph of their deltas shown above. Our RSK04 turbo kit will produce boost pressures of ~20psi through most of the rpm range. Test cell ambient temperature was ~80F for all the tests.

Note that the RS4 and AWE Tuning Audi 2.7T Performance Intercooler Kit temperature drop curves are nearly identical up to approximately 3300 rpms, at which point the AWE Tuning Audi 2.7T Performance Intercooler Kit begins to show superiority. From 3600 rpms and higher, the AWE Tuning Audi 2.7T Performance Intercooler Kit produces nearly an 8 degree F improvement until near redline. The stock intercoolers, however, show their inefficiencies at this high of a boost level, with intake temps drops approximately 40 degree F and 50 degree F lower than the RS4 and AWE Tuning Audi 2.7T Performance Intercooler Kit respectively after 5000 rpms. Even low rpms show the inferiority of the stock intercoolers when running higher boost levels.

The higher the temperature drop, the denser the air charge, resulting in more power and less tendency for detonation.

Why not a FMIC for the 2.7T?

Years ago, we were quite successful with a front mounted intercooler system for the S4 installed on the Blitzkreig Beast, holder of the fastest K03 turbo 1/4 mile record.

However, to fit an intercooler core that was larger than just the cumulative volume of both side mounted intercoolers, an RS4 bumper had to be fitted, along with significant modification to the radiator support. The amount of alterations required to fit a front mounted intercooler that had superior performance over dual side intercoolers practically made it a custom one-off installation.

In order to make a front mount intercooler a simple bolt-in design meant seriously compromising its performance characteristics, which we were unwilling to do. To fit behind an unmodified stock 2.7T front bumper, the intercooler core dimensions had to be reduced significantly. Extensive cutting of the front bumper was not worth the safety compromise in our analysis, given that the vast majority of our clients drive their S4s on public roads.

A brief synoposis of the currently available intercoolers for the Audi 2.7T models:

Download Installation Instructions: Installing AWE Tuning Audi 2.7T Performance Intercooler Kit

Fitment: Audi S4 Sedan 2.7L Turbo Quattro Tiptronic

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AWE Tuning Exhaust had its start in 1991 and has the facilities needed to do everything in house assuring you of a first rate product. Their unique products like the SWITCHPATH AWE Exhaust System for your Porsche is designed to direct exhaust gasses away from the side mufflers giving you that impressive AWE exhaust touring tone only slightly louder and then with the “SWITCHPATH” valve open your exhaust gasses are directed away from the side muffler and you get that more aggressive sound.

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