When factory engineers design an intercooler system for a turbo-charged engine, the main focus is supporting set horsepower and torque figures over a wide range of driving and environmental conditions. When boost levels are increased, such as by adding a chip, the stock intercooler becomes less efficient. In an effort to return the system to OEM or greater efficiency levels, we tested an aftermarket intercooler.
Peak wheel-hp: 202 @ 4874 rpm/peak wheel torque (lb-ft): 242 @ 3030 rpm
Testing Octane: 91
Milltek 70mm turbo-back exhaust with 200-cell metallic HJS catalytic convertor
Forge vacuum-operated bypass valve
Neuspeed High-Flow Turbo Discharge
Dyno Type: Clayton chassis aka 'Mustang'
Temperature: 78 to 86 degrees F
Humidity: 24.7 percent
Transmission Test Gear: third
Notes: Graphs were compiled with data gathered from the factory sensors using VAG-COM diagnostic software from Ross Tech. As well as diagnosing problems, VAG-COM software allows the engine to be monitored. The 2007GTI requires a CAN interface, from $249.