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 Intercooler core measures 24” x 10.2” x 3.54” (610mm x 260mm x 90mm) which is a 71% increase in volume over stock. This allows for a greater volume of air to exchange heat, and provides a dramatic reduction in charge air temperatures to ensure peak performance is achieved and sustained.

Stress testing consisted of 6 consecutive dyno pulls with a 20 second pull and a 30 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 Unitronic Intercooler provided significant reductions in air temperature resulting in a cooler, denser charge air being ingested by the engine, resulting in increased performance.

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 it’s 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”.

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. Like all Unitronic Performance Hardware, this Intercooler offers direct bolt-on fitment, retaining the factory mounting locations in order to simplify the installation process.

With upfront engineering fluid dynamics (EFD), Unitronic is able to hone in and refine the areas that are most effective in meeting our objectives. With the ability to perform different iterations from design changes we are also able to accurately predict how well our hardware will perform. Here is a predictive simulation plot operating within the same conditions it was tested in. Results illustrate and validate the actual data collected.