The Audi SQ7 and SQ8 are two of the most popular performance SUVs in the world. While not as extreme as the RS Q8, the SQ7 and SQ8 are both incredibly capable vehicles. Audi understands that many enthusiasts and gear heads have families and require the space and versatility of an SUV, but don’t want to give up the fun factor. While you may not get the supercar performance straight from the factory, tuning these family friendly SUVs has become increasingly popular.

Like all vehicles, tuning for more boost inevitably causes excessive heat which can damage your engine and hinder performance. The increased boost pressure also puts more strain on some components like the intercoolers. Both these issues can be resolved with the new CSF by PWR Twin Intercooler Set for the 2020+ Audi SQ7/SQ8.

CSF, along with its strategic manufacturing partner PWR, was the first company to introduce a high performance intercooler kit (CSF #8211/8211R) for the 4.0L engines in the Urus / RS Q8 / Cayenne Turbo in May of 2022. They’ve been a huge success and quickly had SQ7/SQ8 owners asking for a kit for their SUVs. With many examples pushing over 800hp, the coolers have proven to be an invaluable upgrade.

While the original kit designed for the Urus / RS Q8 / Cayenne Turbo was able to be installed on the SQ7/SQ8, there were some modifications necessary and not a true “drop-in fit”. Unitronic in Canada really brought the demand for an application specific set of intercoolers to our attention as they have a large customer base of SQ7s and SQ8s. Their tuning suite ups the SUVs power as high as 765bhp & 764 lb-ft. 

The design of the intercoolers is based on the CSF #8211/8211R in which CSF teamed up with leading Southern California VAG specialists, Pacific German from Orange County, CA. They helped to design, develop, and test the new intercooler kit on their very own Lamborghini Urus. You can read more about the original development process here: Lamborghini Urus & Audi RS Q8 High Performance Intercoolers.

Manufacturing of the USA-made CNC billet end tank intercoolers takes place at PWR North America in Indianapolis. This strategic partnership continues to flourish with this exciting new model for the SQ7/SQ8, allowing CSF to bring PWR’s Formula 1 cooling technology to the performance aftermarket.

Design & Engineering

The SQ7/SQ8 Intercoolers have been meticulously designed and engineered to fit exactly like the OEM units they replace. Utilizing all factory mounting points, the installation is straightforward with a “drop-in fit” design. No cutting or modifications are required, and there is no need for aftermarket shrouds or hoses. All mating OEM components can be reused and reinstalled.

There are two available finishes for the intercoolers. A raw billet aluminum finish or Thermal Black Heat Dispersion Cerakote to further the cooling efficiency of these Intercoolers. The Thermal Black coating is able to dissipate heat about 15% faster than raw billet.

OEM VS CSF by PWR

CSF has integrated the charge pipe into the design of the top end tank with an aluminum welded pipe replacing the factory bolt-on plastic part which is sealed with an inner O-Ring. The OEM O-Rings may be a factory design flaw many owners have had to replace them on their stock systems. This failure causes boost leaks and triggers a check engine light which is quite surprising on such a new vehicle.

PWR Intercooler Core Technology

The same intercooler cores used in this application are the same style used in other CSF air-to-air systems developed for the Urus/RS Q8/Cayenne Turbo, Audi RS6/RS7, and Porsche 992 Turbo/S, with incredible results. These cores eliminate heat soak and lower Intake Air Temperatures (IATs) much more efficiently than traditional Bar & Plate designs. This gives us maximum performance for extended periods of time under demanding driving conditions and in vehicles with increased power levels through modifications and tuning.

The 4.0L twin-turbo V8 in the SQ7/SQ8 starts to experience debilitating heat soak and progressively increasing IATs with the OEM intercoolers. This results in the ECU pulling engine timing and drastically decreasing power output. The CSF by PWR Intercoolers solve this issue and allow vehicles to perform at optimal levels consistently and for prolonged periods of time.

CNC Machined Billet End Tanks

As with CSF’s other products produced through our PWR partnership, the new SQ7/SQ8 Intercoolers feature 100% TIG-welded machined billet aluminum end tanks. Compared to the OEM crimped plastic composite end tanks this is a very significant upgrade.

This feature is not only aesthetically pleasing, but is also stronger offering longevity and durability on high-performance vehicles. The CNC machined billet end tanks are ready to withstand increased boost pressures from bolt-on modifications, higher performance tunes, as well as upgraded turbochargers.

Dyno Testing at Unitronic

Unitronic is one of Canada’s premier Audi/VW tuners. They produce a variety of performance parts for popular Audi/VW Models including ECU & DSG Software Upgrades. Unitronic naturally found the SQ7/SQ8’s intercooler weaknesses while developing their tuning software. They highly recommend pairing the CSF Intercoolers with all stages of their Performance Software. The following dyno results are from the 3 stages paired with the CSF Intercoolers.

The SQ7 and SQ8 make an impressive 503 bhp & 596 lb-ft. However, it’s hard driving a turbocharged vehicle without wanting a little more. The Stage 1 software ups the 4.0L Twin Turbo V8 to a healthy 685bhp & 682 lb-ft. This already surpasses the factory output of the RS Q8. The Stage 1+ pumps that up to a solid 717bhp & 714 lb-ft, and Stage 2 makes a whopping 765bhp & 764 lb-ft.

What is truly remarkable about the CSF by PWR systems is their ability to recover and fight off heat-soak. The ability to maintain consistent power (and temperatures) run after run is more important than power gains in any motorsport setting. From our own testing on the RS6 coolers (which use similar core specs as the SQ7/SQ8 coolers), the biggest delta between CSF and OEM is that the performance from the OEM coolers deteriorates quickly after several dyno runs. Compare that to the CSF coolers and they stayed consistent from the first run right through to the fifth. This is especially beneficial for track cars, drag cars and even fast road cars. There’s no power loss because of heat-soak.