Audi TTRS 8S / Intercooler

Revo Intercooler

Audi TTRS 8S 2.5TFSI

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 every restrictive element of the stock cooler, enhancing cooling efficiency by lowering intake air temperatures by up to 55ºC vs. the 8S TTRS intercooler, allowing you to drive harder, for longer.

Key Features

• Bar & Plate Core Design
• Fully Cast End Tanks
• OEM Fitment with Integrated Crash bar
• Intercooler Pipes Included
• Up to 80% Increased Core Volume
• Over 55ºC Lower AIT

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 an 80% larger core volume than the OEM part and offers perfect fitment. By integrating a reinforced OE crash bar, it allows access to a volume of unused engine bay space to be filled with the intercooler core.

End Tanks Design

The stock cast end tanks on the 2.5TFSI cooler do provide elevated performance benefits over the typical plastic end tank coolers. However, the Revo end tank geometry maintains the largest possible cross-sectional flow area to and from the core. The width of the cooler makes for an extremely large volume end tanks, yielding impressive airflow. Coupled with a cast interior surface finish, the Revo end tanks allow air to flow freely without obstructions. 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 between both of these key features.

Bar & Plate

Designed with a bar and plate core to maximise the efficiency of heat transfer, the 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 ambient core side utilises louvred fins to slow ambient airflow which improves heat transfer, while the charge core side features an offset internal fin design to balance surface area and air resistance to minimise pressure drop.

Integrated Crash Bar

To increase the core size and volume the Revo intercooler has integrated an OEM crash bar, requiring extra provisions within the design to ensure correct fitment and crash bar rigidity. The welded connection has been reinforced with plates to transfer any force away from these areas and adding additional safety factors to the assembly. This also allows the dynamic weight of the intercooler to be distributed through the bar, rather than solely relying on the locating brackets at the bottom of the cooler.

Intercooler Pipe Upgraded

Supplied with an upgraded aluminium mandrel-bent throttle pipe and a 6ply silicone charge pipe. The increased diameter pipework ensures the maximum performance by increasing system volume by over 27%. The internal diameter of each silicone is precisely matched to the outer diameter of the ribbed inlet and outlet connections along with a unique Flush Fit design, allowing a smooth transition between components. The throttle hard pipe also includes a water-methanol injection port.

Research and Development

All Revo products are designed in-house using the latest 3D printing technology, CAD and CFD software. Every product is rigorously tested utilising an in-house Hub dyno and Revo data acquisition software. The Revo intercooler minimises turbulence while maximising heat transfer, promoting cooler air temperatures and low-pressure drop. This helps retains power and torque throughout 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 (BETA), a Revo Carbon series air intake system and Milltek downpipe, the Revo Intercooler and pipes were then installed and tested in the same controlled environment to highlight the benefits of enhanced cooling.

Performance Data

Showing the last of six consecutive dyno runs, the efficiency of the Revo Intercooler over the OEM TTRS intercooler is highlighted. With peak gains of +40 HP & +41NM 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,

Inlet Temperature

This is a metric used to confirm that testing on the Revo TTRS 2.5TFSI Intercooler. This is used to show that the air temperatures going into the intercooler were similar for each test, confirming that outlet temperatures shown in the following graphs are purely down to differences in intercooler design/construction. As can be seen, the inlet temperatures during testing were hotter on the Revo Intercooler, yet the Revo intercooler produced the lower outlet temps proving the cooling efficiency.

Outlet Temperature

This is the main performance metric to illustrate that the Revo intercooler far exceeds the stock unit, in fact, one of the most effective Revo intercoolers to date. The graph illustrates the increased cooling performance of the Revo intercooler vs OEM TTRS intercooler over all six runs. The Revo Intercooler provided a massive 57.4°C max and 17.5°C average intake air temperature reduction across the six back to back full gear dyno runs.

Intercooler Pressure Drop Graph

Pressure drop is an important factor when it comes to choosing an Intercooler. The Revo solution features custom cast end tanks to evenly distribute air over the core. This graph highlights that even with massive core size difference there is only a 0.23psi pressure drop in comparison to the stock intercooler, ensuring engine response and minimised turbo lag. You can rest assured that your vehicle will drive and respond as you would expect standard; until you press that pedal!