FORD FOCUS ST MK4/MK4.5 2.3 ECOBOOST
The Revo Intercooler utilises unique design features to lower intake air temperatures, minimise pressure drop and allow the engine to produce impressive power and torque with Revo Software. The unique end tank profile promotes internal laminar flow by decreasing turbulence and increasing airspeed and volume into the bar and plate core. This enhances charge air cooling giving you access to more power throughout the rev range.
The limitations of the stock intercooler were apparent throughout testing with space being one of the largest factors when looking to improve over the stock unit. The stock part consistently struggled to manage charge air temperatures, especially on vehicles with performance software. The Revo Intercooler has been designed to improve on every restrictive element of the stock cooler, enhancing cooling efficiency by lowering intake air temperatures by up to 33.3ºC vs the Stock intercooler, allowing you to drive harder, for longer.
- Bar & plate core design
- Fully cast end tanks
- 20% Increased inlet and outlet diameter
- Intercooler pipes Included
- 13% increase in the frontal surface area
- 28% increase in core volume
- Complete OEM fitment, requiering no modification
OEM VS REVO
When you begin to enhance performance the restrictive OEM intercooler struggles to reduce intake temperatures and flow enough air, robbing the engine of power. One of the largest restrictions we found in the OE unit was the size of the inlet and outlet of the cooler, as you increase the power of the car the charge air temperatures increase, with the increase in charge air temperatures the OE unit starts to become a choking point and increases those temperatures further due to insufficient flow. The Revo Intercooler Kit removes the most restrictive elements, increasing the inlet and outlet sizes combined with a larger core, reducing intake air temperatures and promoting smoother airflow.
INCREASED CORE VOLUME
The Revo Intercooler was built around a simple principle; create a cooler that can keep up with your power demand. Designed from the ground up, the Revo Intercooler has a 28% larger core volume than the OEM part and offers perfect OE fitment with no modification to the bumpers or grill.
INCREASED FRONTAL AREA
Due to the custom-designed end tanks, the frontal area of the intercooler has been increased by over 13%. Offering the best balance between increased performance and acceptable part clearance, whilst also minimising pressure drop.
END TANK DESIGN
The Revo end tank geometry maintains the largest possible cross-sectional flow area to and from the core. With a cast interior surface finish, the Revo end tanks allow air to flow freely without obstructions. The design has been balanced between core width and optimal tank profile design. The inlet and outlet sizes have been increased by 20% over the OE design allowing significantly more airflow and volume, reducing charge air temperatures. End tanks play an important part in maintaining pressure and work in harmony with the core to promote airflow, the Revo end tanks are designed to offer the optimal balance between both of these key features.
BAR & PLATE
Designed with a bar and plate core to maximise the efficiency of heat transfer, the pressure drop is also controlled as the air meets less resistance compared to that of a tube and fin alternative. The Revo Intercooler also features carefully specified fin geometry to maximise cooling properties while minimising flow restriction. The ambient core side utilises louvred fins to slow ambient airflow which improves heat transfer, while the charge core side features an offset internal fin design to balance surface area and air resistance to minimise pressure drop.
INTERCOOLER PIPE UPGRADE
Supplied with upgraded and increased sized 4 ply silicone hoses. The increased diameter silicone hoses allow for increased air volume to the cooler, reducing the heat build up the OE ones suffer at the inlet of the intercooler. The internal diameter of each silicone is precisely matched to the diameter of the Revo intercooler with unique Flush Fit design, allowing a smooth transition between components.
RESEARCH AND DEVELOPMENT
All Revo products are designed in-house using the latest 3D printing technology, CAD and CFD software. Every product is rigorously tested utilising an in-house Hub dyno and Revo data acquisition software. The Revo Intercooler minimises turbulence while maximising heat transfer, promoting cooler air temperatures and low-pressure drop. This helps retains power and torque throughout the rev range as highlighted during controlled Dyno testing.
The Revo Intercooler was tested in-house to compare the performance against that of the stock Intercooler. First tested on a vehicle running the OEM intercooler with Revo Software and a Revo Open Cone Intake System, the Revo Intercooler and pipes were then installed and tested in the same controlled environment to highlight the benefits of enhanced cooling.
Showing the last of six consecutive dyno runs, the efficiency of the Revo Intercooler over the OEM Focus ST intercooler is highlighted. With peak gains of +38 HP (hubs) & +45NM Torque, along with increased performance throughout the entire rev range averaging a gain of +8HP (hubs) and +10NM Torque. The stock intercooler struggles to effectively cool the charge air due to the tube and fin design and restriction in the intercooler inlet and outlet sizes. The Revo cooler is able to cope with the demand far better retaining power even in the harshest of conditions where the OE unit starts to fail.
This is a metric used to confirm the testing on the Focus MK4 ST intercooler. This is used to show that the air temperatures going into the intercooler were similar for each test, confirming that outlet temperatures shown in the following graphs are purely down to differences in intercooler design/construction. However in the case of the Focus MK4 ST OE cooler, due to inefficiency in the OE design of the charge pipes and cooler you can see that the starting temperature is higher from Run1 through to Run6. The main cause of this is again the inlet size of the intercooler and associated pipe work, these parts cause a choking point in the stock system increasing starting temps before they have even been cooled. With the increased size and flow characteristics of the Revo Intercooler and pipes the temperatures are significantly reduced prior to being cooled, a max reduction of 88.3°C and 21.7°C average over six runs. This indicates that the Revo kit can absorb much larger amounts of heat more efficiently than the OE setup, yet the Revo Intercooler produced the lower outlet temps proving the cooling efficiency.
This is the main performance metric to illustrate that the Revo intercooler far exceeds the stock unit. A strong indication that the Revo Intercooler is extremely resistant to heat soak and could likely continue for ten more sequential dyno runs before any significant intake temperature-related issues arose. The graph illustrates the increased cooling performance of the Revo Intercooler vs Focus ST intercooler over all six runs. The Revo Intercooler provided a massive 33.2°C max and 11.1°C average intake air temperature reduction across the six back to back full gear dyno runs, and yet even by the sixth run was still cooler than the starting run on the OE intercooler.
INTERCOOLER PRESSURE DROP GRAPH
Pressure drop is an important factor when it comes to choosing an intercooler. The Revo solution features custom cast end tanks to evenly distribute air over the core. This graph highlights that even with the increased core size difference there is only a 0.09psi pressure drop in comparison to the stock intercooler, ensuring crisp engine response and minimal turbo lag.