CSF High-Performance Intercooler System for C8 Audi RS6 / RS7 [8194]

CSF High-Performance Intercooler System for C8 Audi RS6 / RS7 [8194]

Following the debut of its world-exclusive all-aluminum radiator for the B8 S4 / S5, CSF proudly announces another groundbreaking release: the highly anticipated High-Performance Intercooler System for the C8 RS6 and RS7. In collaboration with Southern California’s leading VAG specialists, Pacific German, CSF has developed this essential intercooler system to unlock the full performance potential and elevate the power goals of the C8 platform. Once again, CSF has partnered with strategic manufacturing expert PWR to deliver Formula 1-level performance to the aftermarket.

Design and Engineering

• The standout feature of the CSF by PWR RS6 / RS7 Intercooler System is its Formula-1 grade intercooler core. Through CSF’s strategic partnership with PWR, this advanced core has been integrated, setting it apart from anything available in the performance aftermarket. Featuring 3mm tall rolled tubes with turbulated inner fins, the design optimizes heat dissipation from the charge air on the pressure side of the intercooler core. Complementing this is the 4.85mm tall multi-louvered fin, recognized as the most efficient in the high-performance industry and delivering performance on par with PWR’s Formula-1 grade race intercooler cores. This proven technology, also utilized in CSF’s air-to-air twin intercooler systems for the Porsche 992 Turbo/S and GT2RS, effectively eliminates heat soak and reduces intake air temperatures (IATs). It enables vehicles to maintain peak performance during prolonged and demanding driving conditions. Dyno testing highlights a significant advantage of CSF’s C8 RS6 / RS7 Intercooler System: its rapid recovery speed in dissipating heat from the turbocharger system. In comparison, the OEM intercoolers on the C8 platform are prone to heat soak, leading to uncontrolled IAT increases. This triggers the ECU to pull engine timing, resulting in reduced performance.

CNC Machined Billet End Tanks

• Like other products developed through CSF’s partnership with PWR, the new RS6 / RS7 Intercoolers feature 100% TIG-welded, machined billet aluminum end tanks, replacing the OEM crimped cast aluminum versions. This upgrade not only enhances aesthetics but also significantly improves strength, ensuring longevity and durability for high-performance applications. The CNC-machined billet end tanks are engineered to handle increased boost pressures from bolt-on modifications, high-performance tuning, and upgraded turbochargers. With the growing enthusiasm among RS6 / RS7 owners, the platform is already exceeding 800 WHP and moving toward four-digit power levels. CSF’s intercoolers are a critical component in achieving these ambitious performance goals.

Dyno Testing  

• CSF performed testing of its intercooler upgrade on a tuned Audi RS6 at VF Engineering using their in-house Mustang four-wheel dyno. The process began with a tuned RS6, completing multiple back-to-back dyno pulls with 50-second cooldown intervals (1-minute cycles, including 10-second pulls). The vehicle was then returned to its OEM tune, and the same testing sequence was repeated to establish baseline data for the stock intercoolers. Once the data was collected, the OEM intercoolers were replaced with CSF’s upgraded units, and testing resumed immediately, adhering to identical procedures with both the OEM tune and VF Engineering’s Stage-2 performance tune. Testing with the CSF intercoolers took place in the afternoon in a dyno cell 8°F warmer than the morning tests conducted with the OEM intercoolers. Despite the higher ambient temperature, the CSF intercoolers delivered substantial improvements. The OEM intercoolers exhibited an average temperature rise of 20°F per pull, while the CSF units achieved a 4°F average temperature drop per pull. At peak performance, the CSF intercoolers ran up to 30°F cooler than the OEM units. The OEM intercoolers began to show heat soak by the third pull, whereas the CSF intercoolers demonstrated nearly instant recovery and showed minimal signs of heat soak, even after the fifth pull.

Specifications

• Number of Tubes:
  • CSF: 45
  • OEM: 22
• Tube Height:
  • CSF: 3mm rolled tube
  • OEM: 7mm
• Fin Height:
  • CSF: 4.85mm
  • OEM: 7mm
• Design:
  • CSF: 100% TIG welded CNC billet end tanks
  • OEM: Crimped w/ gasket cast end tanks
• Tuning:
  • Stage 1: (stock tune) +20 whp / +18 wtq*
  • Stage 2: (with high-performance tune) +10 whp / +20 wtq*

Features

• Sold as a set (left & right)
• Eliminates heat soak and lowers intake air temperatures  for maximum performance in high-performance and race conditions
• Formula-1 performance grade core by PWR (2-row core featuring rolled tubes w/ inner fins)
• CNC machined billet end tanks
• 100% TIG welded vs. OEM style gasket and crimped end tanks for maximum durability
• OEM style inlet / outlet connections for precise fitment with all OEM components
• True plug-and-play “drop-in fit” installation requires absolutely no modifications
• Raw billet aluminum finish
• Available in thermal black heat dispersion cerakote finish
• Made in the USA at PWR North America

Applications

• Audi RS6: C8 (2020+) – 4.0L TT V8
• Audi RS7: C8 (2020+) – 4.0L TT V8

ABOUT CSF

The Racing & High Performance Division of CSF Inc. is dedicated to designing and producing the world’s most advanced, efficient, and dependable cooling solutions. CSF offers a broad range of state-of-the-art cooling systems, with over 250 distinct applications. These include high-performance all-aluminum direct-fit radiators, intercoolers, and oil coolers, as well as bespoke manufacturing tailored for racecars, power sports, off-road vehicles, marine, and industrial applications. Every cooling solution from CSF is meticulously crafted to ensure optimal engine temperature management, even in the most rigorous driving scenarios. With a legacy spanning over 50 years and more than 40 million cooling units distributed worldwide, CSF is widely regarded as a luminary in the industry.