SKU: SKU: AWE4510-11040
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Presenting the AWE Audi 2.7T Performance Intercooler Kit. Cast End Tanks. Carbon Fiber Shrouds. Backed by AWE R&D. If you’re serious about consistent and proven power, read on.
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.
The tested AWE 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 Audi 2.7T Performance Intercooler equals the RS4 intercooler flow rates, and definitively conquers the RS4 intercooler temperature drops.
The construction of the AWE 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 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 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.
Not only did we want the AWE 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 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 Audi 2.7T Performance Intercooler Kit and the RS4 "kits:"
Note: minor trimming may be required. Be sure to refer to the installation instructions in the tab above.
The AWE Audi 2.7T Performance Intercooler Kit comes complete with two AWE Performance Intercoolers, AWE carbon fiber shrouds (air ducts) and a detailed installation manual. No specialty tools are required for install.
The AWE carbon fiber shrouds are also available independently, should you already have the AWE Audi 2.7T Performance Intercooler Set and like to upgrade your shrouds to carbon fiber.
Please note, the AWE 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.
Below are comparison dyno tests, as performed on the AWE Mustang MD-500-SE AWD dyno.
AWE Audi 2.7T Performance Intercooler Kit vs stock intercoolers
(Above) Dyno comparison of stock vs AWE Audi 2.7T Performance Intercooler Kit. Power is to the wheels (multiply by 1.28 for crank power). AWE Audi 2.7T Performance Intercooler Kit horsepower is green line, AWE Audi 2.7T Performance Intercooler Kit torque is blue line.
(Above) Graph of measured differences between baseline and test in dyno sheet of AWE Audi 2.7T Performance Intercooler Kit vs. Stock. AWE 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 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 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 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 Audi 2.7T Performance Intercooler Kit temperature drop curves are nearly identical up to approximately 3300 rpms, at which point the AWE Audi 2.7T Performance Intercooler Kit begins to show superiority. From 3600 rpms and higher, the AWE 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 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.