Forge Motorsport intercooler for VAG EA888 2.0 TSI

The Forge Motorsport race intercooler was developed for EA888 Gen.3 2.0 TSI engines and is an upgrade over the original intercooler. The design makes use of the available space at the original mounting position and improves charge-air flow and cooling.

• Measured gains of up to 16 BHP and 20 Nm of torque
• Intake air temperature reduction of up to 58 %
• 100% direct fitment without cutting components
• High-flow cast end tanks with internal dividers
• Designed and developed in Gloucester, UK

The intercooler replaces the original parts with the following codes: 5Q0145803H, 5Q0145803K, 5Q0145803L, 5Q0145803P, 5Q0145803S and 5Q0145803N.

The intercooler housing on the MQB platform is restricted by available space, as it is installed at the front of the vehicle together with the radiator and air-conditioning condenser. Forge Motorsport therefore used 3D scanning and prototypes to optimise the shape of the end tanks and increase the core depth by an additional 10 mm on older versions of the MQB platform.

The final design has enlarged inlet and outlet openings and greater volume for improved flow. The intercooler is suitable for standard and moderately modified engines, while the design is also prepared for heavily modified EA888 Gen.3 Stage 3+ engines.

To improve flow, the supplied silicone hoses feature a gradual transition around the hot- and cold-side connections. The inlet and outlet connections measure 76 mm instead of the original 63 mm, resulting in a 45 % larger cross-sectional area.

A bar-and-plate core is used, with more than 83 % greater volume than the original intercooler and a 10 % larger frontal area. Different core designs, fin spacing and internal dividers were tested to achieve the best possible balance between flow, pressure drop and cooling.

Test results

Testing on a VTEC four-wheel dynamometer showed an increase in peak power of 16 BHP and torque of 20 Nm at 5500 RPM. The improvement in torque was noticeable throughout the rev range, while the power increase was also evident between 5000 and 6500 RPM.

After more than six consecutive runs, the intake air temperature at 6000 RPM was 34 °C, representing a 58 % reduction compared with 58 °C with the original intercooler. Testing was carried out with the dynamometer room at 23 °C, after first warming the vehicle until the radiator fans switched on and off, bringing the conditions closer to real-world driving.

Lower charge-air temperature means denser air with more oxygen, which contributes to more efficient combustion. At high temperatures, the engine control unit may reduce ignition advance and engine power to protect against detonation; more efficient cooling helps limit this effect.

The intercooler mounts directly to the original mounting points. Installation requires no cutting of components, so the vehicle can later be returned to standard condition. The core and end tanks are protected with a black textured anti-corrosion coating, which also contributes to a more discreet appearance.

Important: the product is intended for EA888 Gen.3 2.0 TSI engines. For vehicles with other engines, the actual engine version and compatibility must be checked before installation.

Suitable for: Audi Q3 II (F3), Audi S3 III (8V), Audi TT III (FV), Audi Tts II (8S), Cupra Ateca I (KH7), SEAT Leon III (5F), SEAT Tarraco I (KN2), Škoda Octavia III (5E3) / III (5E5/5E6), VW Jetta VII (BU), VW Passat B8 (3G), VW T-Roc I (A1), VW Tiguan II (AD1).

Compatible vehicles (manufacturer data)

Before ordering, check that the product matches your vehicle (model, year and engine). If in doubt, write to us — we will check for you.