HF-Series intercooler for Opel Astra G/Zafira A Turbo 2.0, including OPC

This upgraded intercooler kit for the Opel Astra G and Zafira A Turbo 2.0, including the OPC version, is part of the HF-Series range. The high-quality B’n’P core provides excellent cooling performance, even under demanding conditions, while remaining highly robust. It heats up less than comparable cores from other manufacturers. The complete system is designed for optimum flow, resulting in minimal pressure loss, while the entire charge-air path was developed using CAD flow analyses. The cooler end tanks are also made from high-strength cast aluminium.

Product benefits:

• significantly cooler charge air, improving engine combustion,
• quicker engine response,
• improved flow.

This product is suitable for both standard power and motorsport applications, as it also supports substantially higher power outputs. Each intercooler was built for the respective vehicle, calculated using flow simulations and tested on a dynamometer.

Technical details

• Series: HF-Series
• Core design: B’n’P
• Core dimensions: 230 × 265 × 45 mm / 230 × 268 × 80 mm
• Core volume: 2,559 cm³ / 4,931 cm³
• Inlet connection: 42 mm / 60 mm

Road use: A parts certificate (Teilegutachten) is included to facilitate registration of the conversion under §19.3.

Recommended additions

A high-flow intake adapter and an HF-Series boost pipe are also available for this intercooler. Both components can be selected as an additional kit.

Kit contents

• intercooler,
• black silicone boost hose from SF-hoses,
• fitting hardware,
• parts certificate under §19.3.

What does an upgraded intercooler do?

The exact power increase provided by an intercooler cannot be expressed as a single figure, as many factors must be considered, including factory power variation, other hardware modifications and the software used. Results vary from vehicle to vehicle. As a rule of thumb, tuned engines may achieve up to 5–10% more power.

Just as important is the fact that, at high outside temperatures, the intercooler helps prevent power loss or the activation of the temperature protection programmed into many engine control units. This allows the engine to maintain its available power, whether it has been software-tuned or remains standard.

Recommendation for use

The HF-Series intercooler is recommended as part of a combined hardware and software upgrade. Reducing back pressure, which takes load off the turbocharger, and cooling the charge air, which increases the oxygen content in the combustion chamber and reduces thermal load, allows the potential of any turbocharged engine to be used more efficiently.

When carrying out hardware or software tuning, charge-pressure loss must also be taken into account. Increasing power through chip tuning also increases boost pressure in 99% of cases. With the standard intercooler, charge-pressure loss rises exponentially, meaning that the turbocharger has to work harder. This increases its thermal load, reduces service life and accelerates wear due to higher rotational speeds. HF-Series intercoolers provide the ideal balance between cooling performance and charge-pressure loss.

Suitable for: Opel Astra G (T98) / IV (G), Opel Zafira A (T98).

Manufacturer’s vehicle data

• HF-Series Ladeluftkühler Kit Opel Astra G/ Zafira A Turbo 2.0L inkl. OPC

Original product name by HG Motorsport (»z.B.« = e.g.). Please check model, year and engine of your vehicle before ordering; if in doubt, contact us and we will check for you.

Approval

This part comes with a German Teilegutachten (parts certificate); the document is included. In Germany the part must be entered in the vehicle registration after fitting.