As part of our expanding Mk4 Focus ST product range, AIRTEC Motorsport are proud to launch our secondary intercooler kit for track or fast road use.

The challenge
Due to the limited space available in the upper grille area due to the car’s intake system and ducting, it isn’t possible to fit a full-size front mount intercooler to fill the entire height of the grille. Whilst we do offer an intercooler upgrade that’s deeper (AIRTEC Motorsport Intercooler Upgrade for Focus ST Mk4), we still looked at other ways to improve cooling and reduce charge temperatures without having to cut or modify the car.

The solution
Designed and developed at AIRTEC HQ in the UK, our solution was to develop a secondary intercooler that mounts underneath the car behind the undertray and is fed fresh air from a duct. By adding a second intercooler in place of the pipework section, we were able to offer a huge increase in overall capacity to the entire set up without affecting the original (or AIRTEC Motorsport upgraded) intercooler set up.

Despite this huge improvement, the kit fits neatly behind the undertray and can be reverted back to standard with no issues. The comprehensive fitting kit includes Pro Hoses silicone pipes together with all the required fixtures and fittings, as well as step-by-step instructions.

The testing
Measuring heat rejection levels and intake temperatures during back-to back testing on the road over eight consecutive runs showed that with the secondar

 intercooler in place, heat rejection was improved by 41% whilst charge temps were reduced by half.

Data logging the intercooler outlet temperatures before and after fitting the secondary intercooler revealed a peak decrease measurement of 36.7-degress, which translated to a 76.4% reduction. Further testing revealed the secondary intercooler was able to repeat this kind of improvement, averaging a 72.5% decrease over four back-to-back runs proving the set up works effectively and efficiently.

Please note: Only fits manual gearbox models 

Dimensions:
Capacity: 2.7 litres
Front area: 442cm²

AIRTEC part no: ATINTFO61