VW MK7 Golf/GTI/Golf R Integrated Engineering FDS Intercooler
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.
When you begin modifying your VW MK7/Audi MK3 Golf R, GTI, A3, or S3 it will become necessary to upgrade the intercooler. Once upgrades such as ECU tuning, exhaust systems, and turbo upgrades are introduced, intake air temperatures begin to rise, resulting in massive 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.
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
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.
The IE MK7 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.
About Integrated Engineering
IE Company Overview
Integrated Engineering is dedicated to providing high quality automotive performance products without compromising quality, or reliability. We specialize in making your car go faster for longer with highly engineered products.
Our customers have grown to expect a quality build and finish that we strive to over deliver on, not only to manufacture the best, but to ensure the final product performs as well as it was engineered. This begins with a in-depth design process that can take months to years, and through specialized software the digital product is designed and re-imagined many times over. From here, many products are "rapid prototyped" in a ABS plastic to check dimension, fit, and in some cases application. Many of our high-power performance products such as connecting rods, camshafts, and valve train components undergo hours of ruthless testing on our in house engine dyno. This all ensures that our products have real world-data, for real-world results, on real-world cars. At Integrated Engineering our commitment to bring you the highest quality performance products available with uncomprimised performance truely sets us apart from the rest.
Integrated Engineering was founded in 2007 in Salt Lake City, Utah by Peter & David Blais. Integrated Engineering was started as a Volkswagen / Audi high-performance engineering company specializing in Turbo charged and strong, reliable engine builds. Since then, IE has set a new standard for performance products in many areas including connecting rods, camshafts, valve train, and billet accessories. Integrated Engineering has made a mark in the enthusiast community, and continues to offer the quality and performance orientated product our customers demand.
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