Intercooler For Cupra Formentor VZ5

• Inlet air temp reduction (IATS) of up to 58%
• Made in the UK 
• 76mm inlet and outlets (OEM 63mm)
• 83% volume increase over the OEM 
• No cutting of the vehicle 100% plug and play 
• High flow baffled cast end tanks ensuring optimum air transition for cooling efficiency 
• 5 ply silicone hose kit included.
• Lifetime warranty 

With our extremely successful product line up for the Audi 2.5 TSI equipped vehicles it was logical that Forge Motorsport to do the same with the Cupra Formentor VZ5, as it shares the same heart as the Audi’s RS3, However it may have the same 2.5 TSI engine but the cooling package is fitted to the VZ5 is not! The VZ5 actually has the same intercooler setup that can be found in the Golf R/Audi S3 so what we have here is a hybrid of two platforms. In our development of both the 2.5 TSI and 2.0 TSI we found the intercooling to be a compromised area and  were able to extract large gains with our Forge cooling products for both engines,

Our development engineers have great experience of these previous models to take on the challenge of designing a vastly improved cooling package for the Cupra Formentor VZ5. The outlined brief was to develop an intercooler which utilises the maximum of the space available without modification to the vehicle and ensure a reduction in inlet air temperatures without any negative effects on turbo boost pressures and have scope for high levels of tune of 600 BHP and beyond.

Several baffle configurations were designed, and flow simulated to ensure the maximum performance was obtained to keep the core working at its optimum, along with ensuring all its cooling capabilities had been upheld, and that the total volume of the core internal is utilised for optimum performance.

With an increase in inlet and outlet sizes, we then turned our attention to the design of our silicone hoses. With flow in mind, we have created a step within the hose so where the hose meets the hot and cold side of the inlet and outlet junctions the transition is seamless, this helps to lesson any disturbance to the airflow and prevent unwanted turbulence. To further aid with flow, the inlet and outlets have been increased to 76mm from the OEM size of 63mm which equates to a 45% increase in surface area.

Unlike The Audi RS3/TTRS the Formentor VZ5’s  intercooler housing is particularly restricted and confined to a small amount of space, due to it not only housing the