Race Series FDS Intercooler

The Integrated Engineering Race Series FDS Intercooler is engineered for the Audi B9/B9.5 S4 and S5 3.0T platforms, setting a new benchmark in cooling performance. This intercooler boasts a staggering 280% larger volume than the stock unit, featuring a robust bar and plate core constructed with aluminum end tanks. The massive dimensions of 19.4x16.3x4.5 inches are optimized to utilize every available millimeter of space, delivering unmatched cooling capabilities for high-power builds. At the heart of its performance is IE's Innovative Flow Distribution System (FDS) technology. Precisely shaped fins within the end tanks distribute airflow evenly across the entire core surface area. This ensures more effective heat distribution, faster thermal recovery, and a significant reduction in intake air temperatures (IATs), leading to maximized and consistent power gains. Flow testing indicates up to 81.6% more flow compared to their standard FDS intercooler, with dyno testing showing up to 11.4% lower IATs over consecutive runs on a 650+ WHP vehicle. The intercooler requires the iE Aluminum Charge Pipe Kit (IETPCK6), which is sold separately, to connect to its larger 70mm inlets and outlets. The end tank inlets and outlets are CNC machined with a flat-stop edge and beveled grooves to provide a high-friction surface, ensuring hoses grip securely under high boost conditions. The unit is meticulously TIG welded and leak-down tested, featuring thick-gauge stainless steel mounting brackets and reinforced casting mounts for ultimate strength and longevity. Note that some users have encountered fitment challenges, particularly with UK spec crash bars, which may require cutting and welding. Installation time is estimated at 2-3 hours with pre-installed charge pipes and up to 5 hours with new pipes, though some users have reported longer times if the front clip is not put into service position, which is recommended by some for easier installation.