The challenge
Due to the limited space available in the upper grille area due to the car’s intake system and ducting, it isn’t possible to fit a full-size front mount intercooler to fill the entire height of the grille without significant modification. Whilst we do offer an intercooler upgrade with a deeper core design (AIRTEC Motorsport Intercooler Upgrade for Focus ST Mk4), we still looked at other ways to improve cooling and reduce charge temperatures without having to cut or modify the car.
The solution
Designed and developed at AIRTEC HQ in the UK, our solution was to develop a secondary intercooler that mounts underneath the car behind the undertray and is fed fresh air from a duct. By adding a second intercooler in place of the pipework section after the turbo, we were able to significantly reduce the temperature of the air before it entered the primary front mount intercooler, allowing it to operate more efficiently whilst offering a huge increase in overall capacity to the whole system.
Despite this huge improvement, the kit fits neatly behind the undertray and can be reverted back to standard with no issues. The comprehensive fitting kit includes Pro Hoses silicone pipes together with all the required fixtures and fittings, as well as step-by-step instructions.
The testing
Using a Stage 2 tuned car, measuring intake temperatures during back-to back testing on the road over eight consecutive runs showed that with the secondary intercooler in place charge temperatures were reduced by up to 44 degrees, proving the set up worked effectively and efficiently.
AVERAGE INTERCOOLER OUTLET TEMPERATURE
| WITHOUT 2nd Intercooler |
53.1 |
| WITH 2nd Intercooler |
14.4 |
| Difference |
-73% |
Please note: Only fits manual gearbox models.
Will fit with original boost pipes and intercooler or with AIRTEC Motorsport big boost pipe kit and/or our uprated intercooler.
Dimensions:
Capacity: 2.7 litres
Front area: 442cm²
