OVERVIEW IE B8 A4 & A5 2.0T FRONT MOUNT INTERCOOLER KIT The IE FDS front-mount intercooler kit increases horsepower and eliminates heat soak. Get the most out of your tuned or big-turbo Audi A4 by installing the IE FDS intercooler system. The unit is drop-in and requires no cutting, trimming, or modification. VEHICLE APPLICATIONS A4 2009-2015 (B8 - B8.5) A4 Allroad 2009-2015 (B8 - B8.5) A5 2008-2015 (B8 - B8.5) INTERCOOLER FEATURES Massive Intercooler is over 2.2X larger than stock Extensive quality control and pressure testing Increases horsepower and torque by reducing intake air temp Perfect fit, installs with no trimming, cutting, or modification FDS technology utilizes more intercooler core area than competitors Water/methonal ready bung cast into inlet end tank Large bar and fin core measures 22x16x2.5" Fully machined hose barbs on inlets and outlets Highly visible when using RS4 grille 5 ply silicone hoses to ensure reliability Cast aluminum intercooler end tanks Includes all necessary hardware and hose clamps for installation 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. DYNAMIC STEERING FITMENT Vehicles equipped with Audi's dynamic steering systems include a large cooling loop mounted to the front of the radiator. This cooling loop does not allow installation of the IE intercooler and will have to be removed and replaced with a auxiliary mounted kit. If you have a B8 vehicle equipped with dynamic steering, contact our sales team for a cooling loop solution TECHNICAL FEATURES Increasing horsepower of your B8 A4 is a simple task with several tunes and upgraded turbos available. However, it is important to keep in mind that increasing horsepower will result in heat soak of the stock intercooler and parasitic 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 use 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 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, 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, 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, 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 B8. 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 B8 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, as well as a thorough installation manual. FAQ At what point will I need the IE FDS intercooler for my car? With extensive testing, we have found that cars with stage 2 software or higher will benefit from upgrading the intercooler. It is absolutely necessary to upgrade with a big turbo setup as well. What all is included with the IE FDS intercooler? The intercooler kit includes the direct-fit core and all install hardware including heavy duty black silicone hoses, silicone hose clamps, necessary bolts and washers, and an installation manual. Are there any modifications required to install the intercooler? No! The IE FDS intercooler is a direct replacement for the applications listed above. There is no trimming, cutting, or modification needed for installation. Do I need to purchase anything else to install the IE FDS intercooler? This intercooler includes all necessary hardware and parts for installation. Vehicles equipped with Audi's dynamic steering systems include a large cooling loop mounted to the front of the radiator. This cooling loop does not allow installation of the IE intercooler and will have to be removed and replaced with a auxiliary mounted kit. If you have a B8 equipped with dynamic steering, contact our sales team for a cooling loop solution. What kind of power increase will I see with the IE FDS intercooler? Power increase is dependent on the turbo setup and the boost levels that you are running. The larger the turbo setup and the higher the boost pressure, the larger the gains will be with the IE FDS intercooler. How much horsepower will the intercooler support? We have tested the IE FDS intercooler to over 600hp successfully with room to grow. Supported power is in the 650-700hp range, but will ultimately depend on the turbo setup and operating conditions. About Integrated Engineering: Merging decades of experience with hundreds of hours of prototyping, engineering, dyno testing and daily usage evaluation has output exhaust systems that are the ultimate compliment to your performance car. IE products are proudly engineered, designed, and manufactured in-house, in Salt Lake City USA.
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