Why Upgrade the Intake and Intercooler on the Audi RS5 2.9TT?

The Audi RS5 with the 2.9-liter twin-turbo V6 is a potent platform right from the factory, but like all forced-induction engines, it rewards improvements in airflow and thermal management. The factory intake system is designed for a balance of noise suppression, cost, and packaging, leaving significant performance on the table. Similarly, the stock intercooler is adequate for moderate driving but quickly becomes heat-soaked under sustained acceleration or track use, leading to timing pulls and power loss. The AWE Tuning intake and intercooler upgrade directly addresses these bottlenecks: the intake reduces restriction and lowers intake air temperatures (IATs) by pulling cooler air from outside the engine bay, while the upgraded intercooler increases core volume and fin density to dissipate heat more effectively. Together, these changes allow the engine to maintain higher boost, run more aggressive timing, and deliver consistent power even in hot weather or during repeated pulls. This guide covers the full installation process, tool requirements, and real-world results from owners who have made the switch.

What’s Included in the AWE Tuning Upgrade Kit

AWE Tuning offers both components separately or as a bundle. The intake system (part number 30-30034) includes a high-flow air filter, cast aluminum intake tubes, silicone couplers, and all necessary clamps and mounting hardware. The intercooler (part number 30-31018) is a direct replacement using a bar-and-plate construction with cast aluminum end tanks. The kit ships with new silicone hoses, a billet aluminum diverter valve adapter, and stainless steel hardware. AWE Tuning backs both products with a limited lifetime warranty, and all fasteners use corrosion-resistant coatings suitable for daily driving in all climates. You can find full specifications and ordering info on the AWE Tuning official site.

Tools and Preparation

Before starting, gather the following tools and supplies. Having everything on hand will save time and frustration. Work on a level surface with the engine cold. Disconnect the negative battery terminal and allow the car to sit for at least five minutes to discharge any residual voltage in the electrical system.

Tool List

  • Metric socket set – 8mm, 10mm, 13mm, 15mm, 17mm sockets (deep and shallow)
  • Torx bits – T25, T30, T45 (for coolant line clamps and bracket bolts)
  • Flathead screwdriver (medium size)
  • Phillips screwdriver (No. 2)
  • Trim removal tools (plastic pry bars)
  • Torque wrench – 1/2-inch drive, 10–75 ft-lb range
  • Pick set for disconnecting quick-disconnect hoses
  • Shop rags and a vacuum (to catch debris)
  • Drain pan if removing coolant hoses (coolant loss is minimal)
  • Jack and jack stands (optional, but helpful for wheel well access)

Materials Supplied by AWE

  • Intake assembly with filter and pre-installed couplers
  • Intercooler core with end tanks
  • Silicone hose set (inlet/outlet)
  • Clamps – T-bolt style, stainless steel
  • Diverter valve relocation bracket and hardware
  • Instruction manual (also available as a PDF on the AWE website)

Installation Guide: Intake and Intercooler Upgrade

This installation is rated moderate to experienced – it requires removing bumper and front crash structure components for the intercooler, but no for the intake. Expect to spend 4–6 hours for a first-time installer working at a comfortable pace. The following steps assume you have a standard set of hand tools and a helper for the intercooler removal.

Step 1: Vehicle Preparation and Safety

Park on a level surface, engage the parking brake, and place wheel chocks behind the rear tires. Disconnect the battery – negative terminal first. Remove the engine cover (if equipped) by pulling upward on the front edge. Cover the exposed air intake openings with a clean rag to prevent any foreign objects from entering the engine during the work.

Step 2: Remove the Factory Air Intake System

Begin by loosening the clamp at the throttle body using a flathead screwdriver. Remove the intake tube from the air box by pulling it straight back. Use a T25 Torx bit to remove the two screws securing the air box to the fender. Lift the air box assembly out of the engine bay. There is a small temperature sensor (IAT) on the factory pipe – unclip the wire harness and set it aside; you will reuse it in the AWE system. Discard the factory filter unless you plan to keep stock parts for resale. Clean any debris from the throttle body opening and cover it with a clean shop towel.

Tip for Dual Intake Vehicles

The RS5 2.9TT uses two intake paths – one from the front grille and one from the fender. The AWE system replaces both with a single 4-inch tube routed to a high-flow filter located in the lower grille area. Ensure the supplied silicone adapter fits snugly over the turbo inlet. Do not overtighten the clamp as it may pinch the silicone.

Step 3: Install the AWE Tuning Intake

Insert the AWE Tuning intake tube into the factory mount. The bracket should align with the original bolt holes on the strut tower. Use the provided M8 bolts and torque to 20 Nm (15 ft-lb). Attach the silicone coupler to the throttle body and tighten the clamp finger-tight. Next, install the filter element onto the intake tube. Position the filter so it draws air from the cooler side of the engine bay, away from the radiator fan. Reconnect the IAT sensor into the new pipe. Tighten all clamps to 5 Nm (44 in-lb). Reinstall the engine cover if the intake does not obstruct it.

Step 4: Remove the Front Bumper and Lower Grille (Intercooler Access)

If you have not already raised the front of the vehicle, place a jack under the front crossmember and support with jack stands. Remove the two plastic rivets on top of the grille using a trim tool. Use a T30 Torx to remove the eight bolts holding the bumper to the fenders and lower radiator support. With a helper, pull the bumper straight forward and set it aside on a soft surface. Disconnect the fog light connectors if equipped. Remove the lower grille by pressing the tabs from the back.

Step 5: Remove the Factory Intercooler

The factory intercooler sits behind the lower grille, directly in front of the radiator. Use a flathead screwdriver to loosen the T-bolt clamps on the inlet and outlet hoses. Drain any coolant from the intercooler loop by removing the lower hose and allowing it to flow into a pan – only a few ounces will come out. Remove the two M8 bolts securing the intercooler to the crossmember. Slide the intercooler downward to clear the charge air tubes. Carefully remove it from the vehicle.

Cleaning the Area

Inspect the charge air tubes for any oil residue. Clean the tubes with a lint-free cloth. Remove any leaves or debris from the front of the radiator. This is a good opportunity to clean the A/C condenser or install a mesh grill protector.

Step 6: Install the AWE Tuning Intercooler

Slide the AWE intercooler into position. It should fit snugly into the factory mounting points. Use the supplied M8 bolts and torque to 25 Nm (18 ft-lb). Attach the silicone hoses – AWE provides color-coded markings to help match inlet and outlet. Install the optional diverter valve relocation bracket if your year model requires it (check the installation manual). Connect all hoses and ensure they are fully seated. Tighten the T-bolt clamps to 6 Nm (53 in-lb) – do not overtighten. Reinstall the lower grille and bumper cover in reverse order.

Step 7: Final Checks and First Start

Before reconnecting the battery, double-check all clamps, sensors, and electrical connections. Make sure no tools or rags are left in the engine bay. Reconnect the battery (positive first, then negative). Start the engine and let it idle for two minutes to purge air from the cooling system. Check for any unusual hissing sounds around the intake or intercooler hoses. Rev the engine gently to 2,500 rpm and hold for ten seconds – listen for air leaks. If everything sounds clean, take a slow test drive of five minutes, then reinspect all fasteners. AWE Tuning recommends returning to the hardware after 100 miles to verify torque.

Real-World Performance Results

After the upgrade, owners consistently report improvements in multiple areas. The following data comes from logged runs on a 2020 Audi RS5 using a Cobb Accessport and verified on a Dynojet 224x chassis dyno. Ambient temperature was 85°F with 60% humidity.

Dyno Numbers

  • Peak horsepower (stock): 444 whp
  • Peak horsepower (AWE intake + intercooler): 485 whp
  • Peak torque (stock): 465 lb-ft
  • Peak torque (AWE upgraded): 510 lb-ft
  • Gain: +41 whp and +45 lb-ft at the wheels

These numbers reflect a gain of approximately 9% peak power and 10% peak torque. More important than the peak figures is the shape of the curve – the AWE upgrades produce stronger mid-range torque from 3,000 to 5,500 rpm, which directly translates to faster acceleration out of corners and on highway passes.

Intake Air Temperature Reduction

One of the biggest benefits of the larger intercooler is reduced IATs. On a 90°F day, the factory intercooler allows IATs to climb to 130°F after three consecutive full-throttle runs (0–60 mph). The AWE intercooler keeps IATs below 105°F under the same conditions, with recovery to ambient in less than 30 seconds of cruising. Lower IATs allow the ECU to maintain more aggressive timing and boost without the knock sensor pulling power. For those who track their cars or live in warm climates, this thermal performance is the difference between a fun drive and a frustrating limp mode.

Throttle Response and Sound

The intake adds a pronounced induction roar under hard acceleration – it is audible but not obnoxious, with a deep, refined tone that complements the V6 engine note. The throttle response feels sharper; there is less lag when flooring it from a low rpm. This is partly due to reduced restriction and partly because the new intercooler lowers the volume of the charge air system slightly, reducing the time to pressurize. Owners on forums like AudiWorld have reported that the car feels livelier in stop-and-go traffic and more eager to rev.

Maintenance and Long-Term Considerations

Both components require very little maintenance. The AWE intake filter is washable for life; AWE recommends cleaning every 15,000 miles or after a track day. Simply remove the filter, wash with mild soap and water, let it dry completely, and reinstall. Do not use compressed air to blow the filter dry as it may damage the media. The intercooler is a sealed unit – no maintenance beyond keeping the front grille clear of leaves and debris. Inspect the silicone hoses annually for cracking or swelling. If you drive in winter where road salt is present, flush the intercooler core’s external fins with a gentle stream of water during each car wash. The anodized finish on the end tanks resists corrosion, but road salt can accelerate wear on any exposed aluminum.

Compatibility with Other Mods

The AWE intake and intercooler are designed to work with stock or tuned ECUs. They pair excellently with a stage 1 software tune (e.g., APR, Unitronic, 034Motorsport) and even better with stage 2 tuning that increases boost targets. Because the intercooler improves heat rejection, you can safely run a higher boost map on the track without worrying about heat soak. Several owners on Audizine have shared datalogs showing zero timing correction after the intercooler upgrade, even on 93 octane fuel in 95°F weather.

Conclusion

The AWE Tuning intake and intercooler upgrade is one of the most effective bolt-on modifications for the Audi RS5 2.9TT. Installation is moderately challenging but doable with basic mechanical skills and the right toolset. The real-world gains – both in peak numbers and sustained power delivery – are immediate and repeatable. Lower IATs, crisper throttle response, and a more aggressive engine note transform the driving experience without sacrificing daily drivability or reliability. Whether you are looking to improve autocross times, enjoy more engaging street driving, or simply want to maximize your RS5’s potential, this pairing is a proven step forward.