The APR Intercooler System is a OEM-location upgrade that dramatically reduces intake air temperature (IAT), minimizes heat soak, and provides increased performance! The system is a direct bolt-on upgrade that requires no trimming and is recommended at every stage of performance.
Dramatically lowers intake air temp (IAT)
Increases horsepower while minimizing power-robbing heat soak!
Effectiveness tested to over 500 HP!
21 horsepower gain over the factory system!
Massive core size
Use of the OEM-location allows for a massive intercooler core.
24.25" x 16.25" x 1.25" – 492.5 in³ – OEM GTI
24.25" x 16.25" x 1.37" – 529.8 in³ – OEM Golf R
24.00" x 16.25" x 2.25" – 877.5 in³ – APR
Intercooler installed in the best location for this platform
Utilizes factory air dams for exceptional airflow across the core.
100% compatible with the Adaptive Cruise Control (ACC) system.
Highly effective core design
Bar-and-plate core with staggered and louvered fins.
Rigorous testing determined core style, fin density, and size.
Low pressure drop + highly effective cooling = high performance!
Smooth cast end tanks
Engineered for low turbulence/restriction and maximum flow.
Organically shaped to promote airflow across entire core.
Pressure tested to prevent power robbing boost leaks.
No hidden labor costs or permanent modifications
No trimming, cutting, or other costly modification required.
No modification to the Adaptive Cruise Control System required.
Full directions and APR world-renowned customer support included.
Designed by engineers with lasers
With the best equipment and smartest engineers, it just works!
Intercooler Core Design
The APR Intercooler core is a large bar-and-plate design featuring densely packed staggered and louvered fins. This design offers exceptional cooling while balancing pressure loss across the core, and maintaining critical airflow to the components behind the intercooler system. The core size was appropriately matched to the platform, minimizing pressure drop while leaving adequate space for appropriately designed end tanks. To APR’s mechanical engineering experts, the design represented the ultimate in performance, far exceeding the capabilities of the factory intercooler. To the driver, the result is simple: Repeatable performance, even in the most demanding of situations!
Core Style / Internal Fin Structure:
APR’s Engineers paid close attention to the balance between core effectiveness and pressure drop through the core, core style and fin density. With fin density too low, pressure drop decreases dramatically, but typically results in a core incapable of effectively cooling. Likewise, with fin density too great, pressure drop increases dramatically, resulting in the turbocharger working harder, and hotter, to produce the same level of airflow. By fine tuning this often unseen balancing act, as illustrated below, APR’s Engineers were able to maximize performance.
Intercooler End Tank Design
To fully utilize the massive core, APR’s mechanical engineers designed cast aluminum end tanks organically shaped for proper airflow distribution across the entire core. By correctly sizing the intercooler core, end tank design was not sacrificed. The one-piece end tanks are CNC machined to provide a slip resistant mounting surface for hoses, precise integrated mounting surfaces, and perfectly flat connecting surfaces used for TIG welding the tanks to the core. Through proper alignment in welding jigs, each unit is assembled to tight tolerances for a precise and accurate fit.
Pressurized Computational Fluid Dynamic (CFD) Analysis:
APR’s Engineers determined the proper end tank design, for this application, with the help of pressurized CFD flow analysis via the SimuTech Group, and finally through real world testing. During the analysis, the effect of directional vanes were studied to test their ability to aid in airflow distribution. Analysis concluded there was no perceivable benefit on this application as the vanes only added more weight to the system. Real world testing without directional vanes resulted in a +0.5 °C to -0.5 °C temperature spread from the bottom to the top of the core on the outlet side, throughout the various back-to-back tests, further concluding the design maximized cooling effectiveness of the core.
Internally APR conducted a multitude of tests while choosing the appropriate intercooler core and end tank design. Thermocouples were placed at the top and bottom of the core to measure cooling effectiveness and cooling distribution across the entire unit. Pressure transducers were placed at the inlet and outlet of the intercooler to determine pressure loss across the various units. With this information, APR’s engineers specified the appropriate intercooler core type, dimensions, cooling fin density and made the necessary design changes to the end tanks to ensure full utilization of the entire core.
The end result was development of a system that’s much more effective at cooling compared to the factory GTI and factory Golf R intercooler system. Effectiveness is measured as (Intercooler Inlet Temp – Intercooler Outlet Temp) / Intercooler Inlet Temp. The APR Intercooler system’s effectiveness under the most demanding situations was between 82-83% while the factory GTI struggled at 60% and the factory Golf R at 65%.
Intercooler placement plays a critical role in overall performance. By utilizing the factory mounting location, APR’s engineers were able to design a core featuring a massive frontal surface area and large core volume, which plays a critical advantage over common short and stubby front mount designs. Utilization of the factory location means the core receives a high volume of pressurized airflow spread across the entire unit thanks to the highly engineered factory air dam system. Furthermore, by keeping the intercooler in the OEM-location and balancing core fin density, the factory air-to-water cooling system is not disrupted, which is ever so critical on this platform due to the use of an integrated cylinder head manifold cooling system.
The APR intercooler system simply fits, which helps save on hidden labor charges during the time of install. There are no compatibility issues with active cruise control (ACC) systems and the design leaves room for future engine / transmission oil cooling upgrades for track-going customers. The intercooler installs without trimming any air dams, core supports, or more. There’s no drilling, or permanent modifications to the vehicle. Simply follow the included directions and enjoy!
Make Model Engines Part Price
Audi A3 / S3 - (Typ 8V / MK3) 1.8 TFSI / 2.0 TFSI - (EA888 Gen 3)
Audi TT / TT S - (Typ 8S - MK3) 1.8 TFSI / 2.0 TFSI - (EA888 Gen 3)
Seat Leon / Cupra - (Typ 5F - MK3) 1.8 TSI / 2.0 TSI - (EA888 Gen 3)
Skoda Octavia / VRS - (Typ 5E - MK3) 1.8 TSI / 2.0 TSI - (EA888 Gen 3)
Skoda Superb - (Typ 3V - B8) 1.8 TSI / 2.0 TSI - (EA888 Gen 3)
Volkswagen Golf / Sportwagen / Alltrack / GTI / R / Clubsport / ED40- (Typ 5G - MK7)
1.8 TSI / 2.0 TSI - (EA888 Gen 3)
Volkswagen Passat - (Typ 3G - B8) 1.8 TSI / 2.0 TSI - (EA888 Gen 3)
Volkswagen Tiguan - (Typ 5NA - MK2) 1.8 TSI / 2.0 TSI - (EA888 Gen 3)
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