ZERONINE Design HVF Performance Intercooler Upgrade - Ford Focus RS Mk3

The ZERONINE DESIGN Performance Intercooler for the Mk3 Focus RS is a high-efficiency, direct-fit upgrade engineered to offer a significant improvement in charge air cooling, this intercooler is ideal for fast road cars, tuned vehicles, or those preparing for more demanding use.

Our uprated intercooler features a substantially larger core volume than the standard Ford item, offering improved thermal efficiency and reduced intake temperatures even under sustained load. Enhancing performance further is the optimised cast end tanks, complete with larger ports for increased flow and an internal deflector for enhanced airflow management into the core - we also include larger bore silicone hoses as part of the kit.

Whether you're increasing boost levels or simply want to maintain your engine's performance and stop it from derating when hot, this is the solution built for reliability and performance.

Key Features and Performance Advantages:

• Larger Core for Better Cooling – A high-flow, bar-and-plate core with greatly increased surface area helps manage charge temps more effectively than the restrictive OE unit.
• Oversized Inlet & Outlet Ports – We’ve increased port sizing over the factory design to promote smoother airflow and support higher horsepower levels with less pressure drop.
• Larger bore silicone boost hoses supplied as standard with this kit
• Flow-optimised Cast End Tanks – Designed to reduce turbulence and distribute airflow evenly across the core for consistent charge temps across all cylinders.
• Fully CNC-Machined Flanges – Ensures perfect sealing and fitment every time, no compromise.
• Factory Fitment with Performance Gains – Bolts directly to OEM mounting points with no cutting or fabrication required.
• Powder Coated Finish for Durability – Resists corrosion and offers a clean, stealthy aesthetic behind the bumper.

Why Upgrade to the 09D Intercooler?

The factory intercooler is built to meet minimum requirements. It doesn’t take much additional power or heat to push it beyond its limits, especially during back-to-back runs or warm climate use. Our solution addresses these issues by:

- Lowering intake air temps to improve combustion efficiency.
- Reducing heat soak during prolonged driving.
- Supporting future power upgrades thanks to the larger core volume and port sizing.
- Maintaining response and drivability with minimal pressure drop.