The efficiency of an intercooler in any turbocharged engine is absolutely crucial to the overall performance of the engine. Because turbochargers generate a tremendous amount of heat, it becomes necessary to drastically cool their charged output air before it enters the intake manifolds, and further along into the combustion chamber. Why? Colder air is more dense and contains more oxygen then warmer air. Because of this, the engine's management system can introduce a higher proportion of fuel into the mixture, which in turn creates more power.
The specific design of an intercooler also plays an extremely important role in overall performance. It has to physically fit in the vehicle and provide an unobstructed air path between the turbocharger and the engine, all while cooling charge air temperatures by up to 50%. The Champion Motorsport 2010 intercooler upgrades for the 911 Turbo are simply the best-fitting and most functional intercoolers available today. Champion begins by reverse engineering the OEM intercooler to break it down into its positive and negative aspects. Once this is done, the components were re-drawn into the CAD system, where areas of restriction were clearly identified and improved using processes such as CFD (computational fluid dynamics), which test and verify air flow through the part. Lastly, an SLS model of the improved part was created to test fitment and also to create other kit components, such as hoses and hardware.
In order to minimize restrictions in airflow, the core of the Champion intercoolers was specifically designed for this application, as opposed to being cut from a "sheet" of core material. This design allowed the core material to be shifted under the end tanks, gaining an extra row of charge air passage on each intercooler when compared to a Bell core, which is commonly used by other manufacturers. In fact, when compared to the Bell core intercooler and the OEM part, the 2010 CMS intercoolers flow 283 CFM (cubic feet per minute) in comparison to 264 CFM for the Bell core, and 261 for the OEM. Clearly, flow was increased, but how about thermal efficiency? During testing on a typical HOT Florida day with ambient temperatures near the high 80's, the CMS 2010 intercoolers produced an outlet temperature of only 100ºF which is over 50ºF cooler then the OEM intercooler and nearly 30ºF cooler then the other core designs. This testing was done in 4th and 5th gear with an ECU tune pushing 2350mb of boost.
The results clearly show that bigger is not always better. The CMS 2010 intercoolers not only fit better then any other intercooler on the market but they also work better too. Please take a moment to watch the video below featuring Champion Motorsport Technical Director Louis Milone as he explains a little bit more about the CMS intercoolers and why they're the easy choice for your 911 Turbo.