Upgrade your existing intercooler to an Evolution
Racewerks Competition Series Intercooler for improved cooling, and
noticeable gains in
power. The Evolution Racewerks Intercooler has been in development
for over a year on and off the track, and has had 6 design revisions to improve
cooling efficiency and flow characteristics. Dyno tests have proven the
intercooler to show gains of 15 - 25
horsepower at the
wheels, and even more on high boost applications.
Features
The heart of the Evolution Racewerks
Competition Intercooler is the massive 20”x5.5"x6” (26.5”x5.5"x3” with end
tanks) high density bar and plate intercooler core. It features 660 cubic inches
of very efficient high density bar & plate core, versus the factory 425 cubic
inches. Through extensive testing of different types of intercooler cores
Evolution Racewerks found that the high density bar and plate core to be the
most efficient. Independent testing has
shown that the Evolution Racewerks Intercooler is so efficient in cooling that
it has cooled intake air temperatures to almost ambient (outside) temperatures.
Evolution Racewerks also did extensive testing on the proper size to use to
effectively cool the hot charged air as well as fight off “heatsoaking”.
“Heatsoaking” is not an issue at all as shown by consistency of the Intake air
temperatures staying in the same temperature range throughout the
WHOLE RPM powerband. Evolution Racewerks'
Competition Intercooler is just what it is, designed for competition. Evolution
Racewerks has tested their intercooler in 100+ degree heat, on their time attack
race car and have had no problems with heatsoaking.
With it's size and ability to support over 600hp, it is most
likely the last intercooler you will ever buy.
- Large 20"x5.5"x6"
intercooler core
- Cast end tanks
for improved durability and flow
- Available in polished or anodized
black finish
- Includes all aluminum intercooler
piping, which replaces all OEM rubber hoses with hard piping for
improved throttle response and faster turbo spool up
- Piping features beaded ends,
silicone "hump" hoses, and T-bolt clamps
- Maintains all factory components
- All hardware needed to install is
included
- Limited lifetime warranty
- 15 - 25
horsepower gains at the wheels
Application
- 2008+ 135i
- 2007+ 335i/335xi
(Coupe/Sedan/Convertible)
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Design
One of the most overlooked aspect of
intercooler design is the intercooler end tank and piping. Having shorter and
less bends on the intercooler piping will promote better internal flow. This
helps in reducing turbo lag, increase throttle response and faster boost
spool ups. An intercooler end tank must be designed to channel and
distribute air coming in from the inlet efficiently throughout the intercooler
core. Evolution Racewerks' end tanks design has been revised numerous times to
promote smooth internal air flow. The cast end tanks allow a smooth radius on
the inner edges of the end tank, causing less turbulence. The inlet pipe angle
has been changed to provide a smooth entry into the end tank and removes an
extra bend that the factory hoses have. Rubber hosing expands under boost
pressure. This expansion disrupts internal flow and causes turbulence, all of
which slow down airflow velocity (which causes slower boost spool up and
decreased throttle response). By replacing
the factory rubber hoses with hard piping, noticeable increases in boost spool
up and faster throttle response can be seen.
Placement
Evolution Racewerks' Competition Intercooler
sits in the factory location underneath the radiator. Why you ask? The
radiator fan and radiator shrouding extends from the radiator above towards the
bottom, directly behind the factory intercooler. By siting the intercooler in
the same location, we can take advantage of the radiator fan pulling air through
the intercooler core. This makes for even greater efficiency, just like how the
BMW engineers designed it to do. With the optional carbon fiber shroud ducting,
even greater efficiency can be had. The carbon fiber shrouding channels airflow
from the center grill to the intercooler core. Air wants to travel through the
path of least resistance, which in this case is around the intercooler core
instead of through it. The carbon fiber shrouding prevents this and forces air
to travel through the core. Even with a small fan on the dyno, intake air
temperatures are still very low. Also, by maintaining the factory
configuration, we do not block airflow to the radiator at all.
Performance
Unlike turbo kits and other parts where the
main power adder is constant, intercooler gains is based largely on how badly
the current intercooler setup working and will vary from setup to setup. Dyno
graphs do not properly show the performance of intercoolers, intake air
temperatures do as that is the job of the intercooler. A car running factory
boost pressures and The Evolution Racewerks' Intercooler will see lower gains
than another car running more boost with the same intercooler. Even running
upgraded downpipes and exhaust will affect overall gain.
You will see a 15 to 25 hp to the wheels gain
based on your modifications. On high boost cars, we have seen 25+ hp gains.
Available Intercooler Kits
There are three available intercooler kits
available:
Basic - This kit includes the
intercooler assembly, upper intercooler piping, silicone hump hoses and T-bolt
clamps. Everything is included in the kit that is needed to install the
intercooler on your vehicle.
Standard - The standard kit
consists of everything included in the basic kit but adds the diverter valve
pipe upgrade. The diverter valve pipe upgrade allows easy upgrades of the
Diverter Valve. Changing the factory diverter valves to aftermarket units will
help increase throttle response as aftermarket units tend to react faster and
can hold higher boost pressures.
Full - The full kit consists of
everything included both the basic and standard kits but adds the intercooler
carbon fiber shrouding kit. The carbon fiber shrouding channels airflow from
the center grill to the intercooler core. Air wants to travel through the path
of least resistance, which in this case is around the intercooler core instead
of through it. The carbon fiber shrouding prevents this and forces air to
travel through the core.
