IE Race Series FDS Intercooler System For Audi B9/B9.5 S4 & S5
Fits: Audi B9/B9.5 S4 & S5 3.0T EA839 When the factory intercooler becomes the limiting factor, intake air temperatures climb quickly, timing is pulled, and power becomes inconsistent. The IE Race Series FDS Intercooler was engineered for high-output EA839 builds requiring significantly more cooling capacity than the factory system or typical aftermarket upgrades. Unlike conventional intercoolers that concentrate airflow through the center of the core, IE's patented Flow Distribution System (FDS) uses internally engineered end tanks to distribute charge air across the entire core. By utilizing more of the available cooling surface, the intercooler is able to reduce heat soak, improve temperature recovery, and maintain more consistent charge air temperatures during repeated acceleration. At the heart of the system is a massive 19.4" x 16.3" x 4.5" bar-and-plate core delivering approximately 280% greater core volume than the factory intercooler and 55% more volume than IE's standard FDS intercooler. Large cast aluminum end tanks, CNC-machined connections, and hand TIG welded construction ensure durability under elevated boost pressures while minimizing pressure loss through the system. Features Massive bar-and-plate intercooler core Patented Flow Distribution System (FDS) 280% increase in core volume over factory 55% larger than the IE standard FDS intercooler Cast aluminum end tanks CNC-machined inlet and outlet connections Hand TIG welded construction Pressure tested before shipment Stainless steel mounting brackets Direct bolt-in installation No cutting or permanent modifications required Technical Specifications Specification Value Core Type Bar-and-Plate Core Dimensions 19.4" x 16.3" x 4.5" Core Volume Increase +280% vs OEM Increase vs IE Standard FDS +55% Construction Hand TIG Welded End Tanks Cast Aluminum Mounting OEM Replacement Why Flow Distribution Matters Most intercoolers feed the majority of incoming air through the center of the core, leaving the outer sections underutilized. IE's Flow Distribution System redirects airflow throughout the entire intercooler using internally engineered vanes inside each end tank. The result is more uniform airflow across the cooling surface, allowing the entire core to contribute to heat rejection instead of only its center section. Benefits include: Lower intake air temperatures Improved resistance to heat soak Faster recovery between pulls More consistent performance Reduced pressure drop across the intercooler Installation Notes This intercooler is a direct replacement for the factory unit and installs in the OEM location without cutting or permanent modifications. Because the Race Series intercooler utilizes 70mm inlet and outlet connections, it requires the IE Aluminum Charge Pipe Kit (IETPCK6) and is not compatible with the factory charge pipes. Estimated installation time: Approximately 2–3 hours with existing IE charge pipes installed Approximately 5 hours when installing the intercooler and IE charge pipes together Recommended For The IE Race Series FDS Intercooler is best suited for: Stage 2 and Stage 3 vehicles Hybrid turbo setups Ethanol blends Track and road course use Customers looking to maximize consistency during repeated pulls rather than simply lower peak intake temperatures What's Included IE Race Series FDS Intercooler Mounting hardware Installation components Note: IE Aluminum Charge Pipe Kit (IETPCK6) is required for installation and is sold separately. ORT's Take There are a lot of intercoolers available for the EA839 platform, but very few actually rethink how airflow moves through the core. IE's Flow Distribution System is what separates this intercooler from the crowd. Instead of simply making the core bigger, the FDS end tanks distribute charge air across the entire cooling surface, allowing the intercooler to work more efficiently. We also appreciate that IE didn't cut corners on construction. Cast aluminum end tanks, CNC-machined connections, and quality TIG welds make this a product we'd have no problem installing on our own cars. The only thing to be aware of is that this isn't a budget upgrade. The larger 70mm inlet and outlet require IE's Aluminum Charge Pipe Kit, so plan on upgrading both together. It's an added expense, but one that's necessary to take full advantage of what this intercooler is capable of.