Wagner Tuning Audi RS4 B5 EVO 2 Competition Intercooler Kit

Wagner Tuning Audi RS4 B5 EVO 2 Competition Intercooler Kit

The Wagner Tuning EVO 2 Competition Intercooler Kit is a serious cooling upgrade designed for highly tuned Audi RS4 B5 models. By replacing the restrictive factory side-mounted intercoolers with a pair of significantly larger, high-flowing units, this kit helps maintain consistent power delivery, especially during sustained hard driving where the standard coolers tend to heat soak.

An intercooler’s job is simple: it cools the compressed air leaving the turbochargers before it enters the engine. Cooler air is denser, which means more oxygen, better combustion and more reliable performance. When the standard intercoolers get hot, the ECU often pulls timing or boost to protect the engine, and you lose power. A larger, more efficient core helps keep intake temperatures in check so the engine can keep making the power it should.

Core Specifications and Performance Gains

Each intercooler features a competition-grade core measuring 255mm x 260mm x 120mm. Compared with the standard RS4 B5 intercoolers, this gives you:

• 43% larger frontal surface area for greater airflow contact
• 147% more core volume for vastly improved heat dissipation
• Inlet and outlet diameters opened up to Ø65mm to suit higher boost setups

The core uses Wagner’s latest tube-fin technology, designed to balance cooling efficiency with low pressure drop, so you get colder charge air without choking turbo response.

End Tank Design and Construction

The cast aluminium end tanks have been developed using CAD-based flow analysis. The shaping inside each tank is optimised to spread air evenly across the full width of the core and to keep backpressure as low as possible. Even cooling and smooth airflow help the turbos work more efficiently and reduce stress on the system.

The kit also includes carbon fibre air ducts, which guide cool air directly into the cores while adding a clean, motorsport-inspired look to the engine bay.

Fitment and Installation

This kit is designed specifically for the Audi RS4 B5 (2.7 BiTurbo). It uses the original mounting points, which simplifies the core installation, however significant vehicle modifications are required to accommodate the larger intercoolers. The supplied installation instructions must be followed carefully, and the work is best carried out by an experienced workshop.

Please use the vehicle lookup tool or check the Vehicle Fitment tab to confirm compatibility with your specific car.

Key Benefits at a Glance

• Stronger, more consistent cooling under hard or sustained driving
• 43% greater frontal area and 147% more core volume than standard
• Optimised cast end tanks for smooth internal airflow
• Ø65mm inlets and outlets suited to higher boost applications
• Carbon fibre air ducts included for improved airflow and presentation
• Bolt-on fitment using factory mounting points

For owners running tuned RS4 B5s, particularly those with stage 2 or higher software, hybrid turbos, or cars used on track, the Wagner EVO 2 Competition Intercooler Kit is one of the most effective ways to address the heat soak issues that hold back the standard cooling system.