Notes
The problem with the DSG transmission is that no matter what the ECU rev limiter is set to, it will automatically shift at 6600 rpm, effectively limiting the amount of peak horsepower that can be achieved. If the vehicle was equipped with a six-speed manual we would have continued to see gains all the way to 7000 rpm, with a peak of 294 whp @ 6500 rpm on 91 octane.
VF Engineering Stage 2 front-mount intercooler upgrade
*Peak wheel-horsepower: 288 hp @ 6300 rpm
*Peak wheel-torque: 285 lb-ft @ 4400 rpm
*Core type: Spearco bar and plate
*Core size (in.): 20 x 7.75 x 3.5
Pros
*Easily fits behind the stock bumper with zero modifications.
*Supports up to 415 wheel-horsepower.
*Intercooler core features cast end tanks for optimal flow.
*Collector and merger-designed piping incorporates the stock intercooler for increased cooling capacity.
Cons
*The silicon throttle body hose was a bit tight, requiring a good amount of patience to put it on.
*Modification of the foam core support can be a bit tedious.
Parts: Intercooler assembly, silicone hoses, steel pipes, OEM-style hose clamps, mounting brackets, hardware
Tools: T20, T25, T30 Torx, flat screwdriver, spray lubricant, 10 and 13mm socket, hacksaw, extension and ratchet
Price: $695 (with purchase of RS/S kit)
Installation Time: 2.5 hours
Notes: A normal side effect of a larger intercooler upgrade on a stock turbo is a slight shift in the torque curve. But with the large Garrett GT28RS turbo this was not the case and we saw no shift. The dyno showed roughly a 34-percent decrease in the amount of timing retard and a reduction in intake manifold temperatures of 12 percent.
Conclusion
Some might say that this upgrade is wasted on a DSG. They are definitely wrong. A little over a year ago, we did some testing on a few '06 GTI 2.0Ts. One GTI with a six-speed manual produced 355 whp, 288 lb-ft of wheel torque, and it was able to clock off a zero-to-60 time of 5.2 seconds. In comparison, we had a DSG version of the same car with only 217 whp and 216 lb-ft clock off a zero-to-60 time of 5.5 seconds. The thing that impresses me more than the oodles of power and torque is how well-mannered the car is. After the kick in the pants from the boost spike, the power delivery is smooth and linear, and when the DSG shifts at 6600 rpm it is absolutely flawless. So to make this a blunt as possible: there's no surging, pinging, or quirky behavior. With a smooth idle, the DSG does not kick out or slip and shifts are uneventful. In truth, the major concern was what I might have to sacrifice. With about a thousand miles on the kit, I have yet to sacrifice anything. Now my only concern is preserving my driver's license.
Parts Cost
VF 2.0T RS/S Turbo Kit: $5,500
VF Stage 2 Front Mount Intercooler Kit: $695
Motul 8100 X-cess 5W-40 5 liters: $47.50
OEM Oil Filter: $14.50
OEM VW G12 Coolant 1 gallon: $20
Install Cost at VF Engineering:
VF 2.0T RS/S Turbo Kit: $1,000
VF high-flow Front Mount Intercooler Kit: $250
Overall Largest Horsepower gain: 115 WHP at 6,400 RPMOverall Largest Torque gain: 106 WTQ at 4,400 RPM