AWE/S3
Intercooler upgrade
Peak wheel-hp: 237 @ 6407 rpm
Peak wheel-torque: 245 lb-ft @ 3551 rpm
Pros
Being a factory part, it fits perfectly with no modifications, and with factory VW/Audi logos and part numbers, it will fool most dealer techs, making it the ultimate stealth upgrade All-aluminum core and end tanks are welded together, making an airtight seal-a huge improvement over the factory aluminum-and-plastic combo that is prone to leaking Cooling capacity is increased by 30 percent
Cons
Like the factory intercooler, it's still sandwiched between the radiator and A/C condenser (which blocks almost the entire front of the intercooler)
Parts
Intercooler assembly, factory hoses, hardware
Tools
T20, T25, T30 Torx, flat screwdriver, spray lubricant, 10, 13 and 16mm sockets, extension and ratchet
Price
$700
Installation time
2.5 to 3 hours
Recommendations
Use Loctite Blue threadlocker to help secure intercooler bolts. Once installed, they're difficult to access if they vibrate loose.
Notes
We saw no noticeable shift in the boost curve but a nice decrease in intake manifold temperatures.
Conclusion
The K04 kit performed better than expected. Having seen K04 upgrades on many 1.8T engines, we expected a good bump in performance. This went well beyond a bump-more like a leap. Coupled with the S tronic's inherent nature of dropping engine revs right on top of the power curve acceleration builds at a breakneck pace, the car seems to keep going and going.
It's evident there's still more power to be squeezed from the K04 with future upgrades such as a fuel pump, larger injectors and some that haven't been developed yet. This kit is a good, solid base.
To ensure accuracy, we used the same dyno for our entire test, the same tank of gas and tried to hold variables as constant as possible. A few days after the upgrade, we took the A3 with the AWE K04 kit, turbo-back exhaust and intercooler back to dyno B (where the vehicle had made 197 hp stock). It produced 288 hp at 6350 rpm on 91-octane. This shows how the same setup can produce extreme horsepower variations.