GGR large capacity intercooler

We identified the standard Focus RS intercooler as having a major performance shortcoming early on in the development program of our conversions. Controlling the air charge temperatures (ACT’s) on any car – particularly a turbocharged vehicle – is critically important to optimise performance.

Our aim was to develop a direct replacement intercooler which was significantly more effective than the original, yet would fit the Focus RS without additional alterations.

Our new design is a tube and fin alloy intercooler with almost 100% larger cooling surface area, and uses a highly efficient motor-sport core as used on the latest Formula 2 cars (designed by Williams Grand Prix Engineering). It also comes complete with unique flow diverter plates designed to channel cooling air through the unit.

Great care was taken in the positioning of the inlet pipe to ensure the original inlet hose could be used. The original intercooler to throttle body hose is mis-shaped to allow clearance past the coolant radiator outlet. We have re-positioned and angled the intercooler outlet to clear this restriction, and supply a suitable three layer silicone throttle body hose with the intercooler.

On the road and during testing on the chassis dyno the air charge temperatures haven’t exceeded 40 degrees, plus the new intercooler outlet design removes the flow restriction of the original items.