Turning the corner into 2021, the second year of CSF's partnership with Formula-1 Cooling manufacturer, PWR, CSF is excited to officially release to the public the world’s first and only high-performance intercooler upgrade for the new Porsche 992 Turbo and Turbo S (CSF #8188).

With increased power, also comes higher levels of heat generated by the engine system. This is why an upgraded intercooler system is especially important in a turbo application. The new CSF 992 Turbo/S Intercooler System is a “must-have” bolt-on modification, considering the placement of the intercooler system on top of the engine.

Since the inception of the first water-cooled Porsche 911 Turbo with the 996 variant in 2001, the Turbo has been regarded as “the everyday supercar.” With each subsequent model, from 997, then 991, and now with the new 992, the boundaries of usable performance have been pushed on the street, racetrack, and drag strip. The Porsche Turbo is one of the most advanced tuning platforms around the world, with modifications ranging from simple bolt-ons and tunes to built engines, upgraded turbos, and standalone ECU management systems on vehicles pushing well over 1,000WHP.

How The New Porsche 992 Intercooler System Works

Unconventional to the typical individual side-mounted intercoolers behind the ducts of the front doors found in previous water-cooled Turbo models, the new 992 generation has moved the intercooler system to the top of the engine compartment with fresh ambient air now being transferred into the intercooler system through redesigned intercooler ducts sitting beneath the rear decklid.

Cold, fresh air is scooped in by the intercooler ducts, positioned on each side of the car’s rear quarter panels. The air then travels into the inlet tanks on each side of the intercooler system module. The heat transfer process takes place as the charge-air moves through the intercooler core and the ambient air passes through the core from the top intercooler ducts, and exits below the vehicle. The intercooled charge-air from both cores is then merged in the single centre section outlet tank before entering the y-pipe connected to the engine’s throttle body.

The CSF Advantage

Formula-1 Grade Core Technology

The most important feature of the CSF by PWR 992 Turbo/S Intercooler System is the Formula-1 grade intercooler core. CSF’s strategic relationship with PWR has allowed the inclusion of this core, which is unlike any other available in the performance aftermarket.

• 2-Row Core Featuring Rolled Tubes w/ Inner Fins
• 33 Tubes vs. OEM 17
• 3mm Rolled Tube vs. OEM 7mm
• 4.85mm Fin Height vs. OEM 8mm

CNC Machined Billet Construction

The most apparent difference of the high-performance intercooler system from CSF is the beautiful 100% TIG-welded all-aluminium construction, compared to the OEM crimped-on plastic tank design. This feature is especially important in high-boost applications, where the plastic tanks can crack under the stress of higher pressure, or on the racetrack due to higher vibrations.

Industry Leading Dyno Testing by M-Engineering

Working with both Jon and Mitch, owners and lead tuners of M-Engineering, to compare the OEM intercoolers vs. CSF’s High-Performance Intercooler System on World Motorsports‘ state-of-the-art wind tunnel dyno

Below are charts of the data from two pulls, one with the stock intercooler system, and one with the CSF High-Performance Intercooler System. These tests started in 4th gear at 2500RPM, went through a shift into 5th, and then to redline.

Note: Both tests were completed on the same day with the OEM intercoolers tested first at approximately 9:00 AM with much lower ambient air temperature and density altitude (DA). The CSF intercoolers were tested at approximately 2:00 PM. The stock intercooler run had about 40°F cooler intercooler inlet start temps & 20*F cooler IC outlet temps at the start of the pulls, therefore this data has been normalized for real-world results and fair comparison. The spike in boost pressure displayed on these graphs is representing the shift from 4th to 5th gear when the throttle closes slightly.

The CSF intercooler system has proven to be much more efficient throughout the entire rev range, particularly at very high intercooler inlet temperatures (start of the run).

Jon Hebbeln, M-Engineering Co-Owner and Engine Calibrator

The CSF intercooler system (left) side-by-side comparison to the OEM (right), showing better results in intake air temperature (IATs) and intercooler efficiency, all while being tested in hotter conditions. (Orange line on the CSF graph on the left-hand side shows improved performance by approximately 25*F at the end of the 5th gear pull)

Due to the larger and more efficient cores, the CSF intercooler system displayed a slightly higher level of pressure drop with a range of .5 to 1 psi more than the OEM system throughout the dyno test. This is generally to be expected – more surface area, more drag – but with increased cooling efficiency, which the CSF intercooler system provided. Tuning can compensate for this slight increase in pressure drop as well as provide maximum performance output, which can take advantage of the efficiencies and higher performance that the CSF by PWR High-Performance Intercooler System provides. 

992 Turbo S, tuned by M-Engineering – Mods are catless downpipes, tuned on E30 fuel. After installing the CSF intercoolers + retune, increase of ~16 WHP and ~60 WTQ.

CSF High-Performance Intercooler System Features (CSF #8188):

• Eliminates Heat Soak and Lowers Air Intake Temperatures (IATs) for Maximum Performance in Race Conditions – Especially Critical Due to Intercooler Placement in Engine Compartment
• Formula-1 Performance Grade Core by PWR (2-Row Core Featuring Rolled Tubes w/ Inner Fins)
  • 33 Tubes vs. OEM 17
  • 3mm Rolled Tube vs. OEM 7mm
  • 4.85mm Fin Height vs. OEM 8mm
• CNC Machined Billet End Tanks With Integrated Y-Pipe Connection to Throttle Body
• 100% TIG Welded vs. OEM Style Gasket and Crimped Plastic End Tanks for Maximum Durability in High Boost Applications
• OEM Style CNC Machined Inlet/Outlet Connections for Precise Fitment with All OEM Components
• Highly Engineered, Lightweight Design – Weighing Only 20 lbs. Total (9.07 kg)
• True Plug-and-Play “Drop-in Fit” Installation
• R&D and Performance Testing by Industry-Leading Porsche Tuning Companies – M-Engineering, World Motorsports, GMG Racing, and Gosha Turbo Tech
• Made in the USA at PWR North America
• Fits:
  • 2020+ Porsche 992 Turbo
  • 2020+ Porsche 992 Turbo S
  • OEM # 992.145.805.G

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