This part will replace the following OEM parts: 5Q0145803H, 5Q0145803K, 5Q0145803L, 5Q0145803P, 5Q0145803S, 5Q0145803N
⭐ Intercooler both performs and looks unbelievable... definitely does what it says on the tin. 10/10 - Jake, 12/11/2024 ⭐
Following on from our previous intercooler solution for the MK7 golf and MQB chassis variants that utilise the EA888 2.0 GEN3 2.0 TSI engine, we have designed our race intercooler to further enhance performance over the original intercooler and our previous iteration of our cooling solution, designed, developed and tested, at our headquarters in Gloucester UK. Throughout the development process we have strived to improve the efficiency and performance of the EA888 GEN3 engine. Our project brief was to develop an intercooler that utilised all of the available space in the original position of the OEM intercooler along with increasing the size again over our hugely successful product FMMK7FMIC. We also had to ensure the inlet air temperature is reduced, without any negative effects on the boost pressure or engine and transmission cooling.
In the MQB chassis the intercooler housing is particularly restricted and confined to a small amount of space, due to it not only housing the intercooler, but also the radiator and air conditioning condenser. The front panel in theory is a sandwich pack that houses the auxiliary cooling components. This means in order to increase the size of the intercooler without paying detriment to the performance of the surrounding items, and with also having very little extra space available, that it can be very difficult to execute the perfect blend of a high flow intercooler within such a close proximity. Our research and development engineers went back to the drawing board looking at previous documented dimensions while also taking new scans of the intercooler housing, this enabled the team to squeeze a further 10mm in depth of the core that houses very snugly into the earlier MQBs platform.
We also looked at the differences between the Mk7 and Mk8 cooling components and found that the Mk7 Golf GTI and Golf R has a thicker radiator than the MK8 equivalent models thus meaning we also needed to consider any fitment procedures carefully. The design team started to 3d print the intercooler end tanks while creating a test sample dummy core to fit to the Mk7s platform and check for any clearance issues that may occur. The final chosen design has increased inlet and outlet sizes along with increasing the volumetric capacity to increase flow which aids with future proofing the design to work well with highly tuned stage 3 plus EA888 Gen 3 engines as well as offering the best cooling solutions for either a stock or mildly modified powerplant. This gives the best package for the enthusiast as they start their journey in enhancing the vehicles performance.
The 3d printed end tanks and dummy core enabled us to ensure the fit was perfect on the vehicle before any prototype castings or machined billet end tanks were produced ready for dyno testing. Several baffle configurations were designed, and flow simulated to ensure the maximum performance was obtained to keep the core working at its optimum, along with ensuring all its cooling capabilities had been upheld, and that the total volume of the core internal is utilised for optimum performance.
With an increase in inlet and outlet sizes, we then turned our attention to the design of our silicone hoses. With flow in mind, we have created a step within the hose so where the hose meets the hot and cold side of the inlet and outlet junctions the transition is seamless, this helps to lesson any disturbance to the airflow and prevent unwanted turbulence. To further aid with flow, the inlet and outlets have been increased to 76mm from the OEM size of 63mm which equates to a 45% increase in surface area.
The consideration of space and our clever design has led us to produce several intercooler cores with different fin configurations and internal capacities. Depending on the core design, testing results led us to choose a bar and plate design with over 83% more volume than the OEM intercooler, and with a frontal area increase of 10%.
Why do we test different cores?
Here at Forge Motorsport, when developing an intercooler, we will test several different cores for each application. For example, a bar and plate style core, a tube and fin style core along with different fin pitches and heights i.e. 22 fins per inch or 17 fins per inch as well as changing the internal fin pitches/shapes and density within the tube enabling to fine tune the amount of pressure drop the intercooler produces.
Pressure drop is not always a bad thing, as our testing and research has proven on various projects, this is because the pressurized air velocity is being stalled by the pressure drop within the cooler thus allowing more time to cool the air within the cooler itself, as air passes through the non-pressurized face of the core, that is open to the atmosphere. Too much pressure drop can of course have a problem on the higher performance engines as the intercooler reaches its maximum efficiency the turbo has to work a lot harder to force the air through the core. This in turn creates higher inlet air temps (IAT’s) due to the turbo creating more heat as it is over stressed and worked harder. No pressure drop can also prove to be inefficient as the cooler will not lower the charge temperature again resulting in higher inlet air temperatures.
Dyno Results
Testing was completed using Performance Remap in Gloucester with their VTEC 4-wheel drive dynamometer; this was to ensure all our data has been achieved with results as accurately as possible by an independent tuner. Peak p
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Shipping
📦 Regal Autosport Shipping Policy
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We proudly ship our products across the UK, Europe, the USA, Australia, South East Asia, and other locations globally.There are no regions we restrict shipping to.
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In the rare case of lost shipments:
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📦 Regal Autosport Shipping FAQs
Where do you ship to?
We ship across the UK, Europe, the USA, Australia, South East Asia, and worldwide. There are no regions we restrict shipping to.
Which carriers do you use?
UK orders: Royal Mail (small items), DPD Local (parcels up to 30kg)
International orders: Royal Mail (small packages) or DHL Express (larger parcels)
How long will my order take to arrive?
UK deliveries: Typically 1–2 business days after dispatch.
International deliveries: Usually 2–15 business days, depending on location.
Please note: We do not ship on weekends or UK Bank Holidays.
When will my order be dispatched?
Orders placed before 2 PM are usually dispatched the same business day. Orders placed after 2 PM are processed on the next working day.
How much does shipping cost?
Shipping costs are calculated at checkout based on the volumetric weight of your items. We do not offer free shipping — instead, we keep our product prices as competitive as possible.
Will I receive tracking information?
Yes! All shipments are tracked and signed for. You’ll receive tracking information by email and can also track your order via:
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The courier’s own website
Do I have to pay customs charges or import taxes?
UK Customers: Prices include UK VAT.
International Customers:
We deduct UK VAT at checkout.
You are responsible for any local customs duties, import taxes, or fees.
Delivery times may be affected by customs clearance, and time is not of the essence for international deliveries.
What happens if my order is lost or damaged?
If your shipment is lost, we will re-ship your order once the courier confirms the loss.
If your order is damaged, we will work with you to file a courier claim and either replace the item or offer a discount based on the situation.
Please inspect your delivery upon arrival and contact us immediately if there are any issues.
What if my item is on backorder?
Orders containing backordered items will be held until all items are available. We do not split ship orders. If you require partial delivery, please place separate orders for in-stock and backordered items.
Can I collect my order in person?
We do not offer local pickup or local delivery for online orders due to security verification. However, you are welcome to visit our store and pay via chip and PIN if you wish to purchase in person.
