Evolution Racewerks - A4 B6 Sports Series Front Mount Intercooler (FMIC) Kit

After the release of our Competition Front Mount Intercooler (FMIC) that was designed for the "Big Turbo" GT28 variant turbos, were were receiving quite a bit of inquiries and demand to produce a FMIC designed for the stock K03 and K04 upgrade turbos. We were very fortunate to get the huge support we received from the Audi community so the project was a go and we began R&D in Dec. 05. After months of R&D and beta testing, we are proud to introduce the Evolution Racewerks Sport FMIC for the B6 A4.

Ease of Installation: (1 Easy, 5 Hard): 2

Installation Guide

Parts Checklist

Key Features:

1. Properly sized 18"x6.5"x3" (22"x6.5"x3" with end tanks) High Density Bar & Plate Construction Intercooler Core.
2. Rolled intercooler end tank design (welded and port & polished interior for improved flow).
3. Mirror polished or Type III Hard Black Anodizing (for stealth) finish on intercooler, end tanks and all piping.
4. Complete all aluminum intercooler piping, replaces every single OEM piece with hard piping for improved throttle response.
5. Intercooer piping features beaded ends, silicone "hump" hoses and T-bolt clamps to prevent intercooler piping from coming off from boost.
6. Designed for OEM or OEM style diverter valves (non OEM style diverter or blow off valve flange/positioning available upon request).
7. Smog pump relocated to make room for the least amount of bends and shortest intercooler piping possible (for faster response/decrease turbo lag).
8. Maintains ALL factory components, i.e. fog lights, bumper reinforcement bar, smog pump, horn, water squirters etc...
9. Retains the OEM side fog light covers and lower center grill for the OEM look.
10. Includes replacement External Power Steering Cooler kit with all hardware to mount and install that replaces OEM power steering line with more efficient unit. No need to tweak or "rig" the OEM piece.
11. Includes all hardware needed to install.
12. Limited Lifetime Warranty.

Sport FMIC with factory front bumper, center grill on

Sport FMIC (polished version)

The ER Sport FMIC features all the innovations found in our "infamous" Competition FMIC kit, however with a smaller intercooler core that is sized for stock K03/K04 upgrade turbos and can even support the GT28 variant turbos. It also retains the factory bumper reinforcement bar (no modifications needed) instead of having a replacement piece found in the Competition FMIC kit.

At the heart of the ER Sport FMIC kit is a 18x6.5x3 (22x6.5x3 with end tanks) high density bar and plate intercooler core. The same (but smaller) core found in our Competition FMIC that pulls the insane intake air temperatures (IAT). Essentially, the "little brother" to the Competition. Even though it seems compact in size, it is not. It features 351 cubic inches of intercooler core, comparable to the other FMIC's in the market. Instead of going tall and thin like other competitor's FMICs, where half the intercooler is blocked behind the bumper cover and does not receive direct cold airflow, the ER Sport FMIC is short and thick. This puts more than 90% of ER Sport FMIC in direct cold airflow and making the intercooler as efficient as possible. Performance, no compromise. Function over form. With the bumper cover on however, one can hardly tell that the ER Sport FMIC is not tall. With the bumper cover on, it looks just like our Competition FMIC which is tall and thick.

Sport FMICs fresh off production line

Through extensive testing of different types of intercooler cores (tube & fin, bar & plate) we found that the high density bar and plate core to be the most efficient. Independent testing has shown that our FMIC is so efficient in cooling that it has cooled intake air temperatures (IAT) to almost ambient (outside) temperatures. We also did extensive testing on the proper size to use to effectively cool the hot charged air from the K03/K04 turbos, yet still be able to support the GT28 variants that can still fight off “heatsoaking” (when the intercooler cannot transfer heat away faster than the heat building up from the hot intake air). “Heatsoaking” is not an issue at all as shown by consistency of the IAT staying in the same temperature range throughout the WHOLE RPM powerband. Also our FMIC recovers so fast after a full throttle pull that once you shift, the IAT's recover.

As with our Competition FMIC's, the Sport FMIC features a smog pump relocation bracket. The stock bracket holds the smog pump in direct line of the shortest path to the FMIC. We relocate the smog pump bracket so that we can get the shortest amount of piping with the least amount of bends for increased throttle response and faster spool up. Again, performance, no compromise. Our intercooler end tanks feature a "rolled" design and are ported and smoothed out on the inside for better flow, again, helping with throttle response and faster spool up. Our intercooler end tanks are welded inside and out as well to ensure strength. We supply a new more efficient external power steering cooler to help dissapate heat from the power steering fluid (Audi power steering pumps are prone to failure) and does not require you to "rig" the old power steering cooler to work with the FMIC.

All our intercooler applications come standard with a mirror polish intercooler and piping. We also offer and stock our intercooler applications with Type III Hard Black Anodizing for the guys that want the stealthy look. With the Type III Hard Anodized FMIC, it is very hard to tell there is a FMIC on the car. Most of our customers with the Type III Hard Anodized FMIC comment that unless you know there is a FMIC on the car, nobody notices it. Another added benefit of the Type III Hard Anodizing is that it makes the intercooler fins harder and stronger, which makes it less prone to getting bent/damaged from road debris like rocks etc... We opted for the Type III Hard Anodizing over the Type II color anodizing which is only asthetics for this purpose only (even though it cost us considerably more to anodize Type III than Type II). We have been using Type III Hard Anodizing on FMIC we put on our rally car customers for years which go through tremendous amounts of abuse. Testing has shown no noticeable ill-effect from the Type III Hard Anodizing on performance (regular spray paint etc... has shown ill-effects on performance).

We also offer our intercoolers in any color of the rainbow you want (special order) and is available in only Type II Anodizing (asthetics).

Quality is very important to us. We do extensive R&D as well as beta testing to ensure this (as some of you may already know, waiting for us to release the production units). We only release our products once we feel we have reached perfection. We do not rush to get our products out even if there is alot of potential customers. Also, we do quality checks before the intercoolers are packaged. All our FMIC’s are pressure tested to 50 PSI of pressure before they are shipped. We include only high quality parts and accessories in our FMIC kit. We include detail instructions and ALL parts needed for installation. All our FMIC’s are backed with our Limited Lifetime Warranty.

We go through extensive R&D to test all the innovations and features we incorporate into our intercooler systems. With years of experience building race cars and high power street cars, you can be sure that you're getting the best.