AIRTEC Motorsport 60mm Core RS500-Style Intercooler Upgrade for 3-door and Sapphire Cosworth

Available as Pro Series Black or Natural Silver

Please note: This will NOT fit the Escort Cosworth – please see other listing


From £434.05 (inc VAT)
£361.71 (exc VAT)

Technical Data

As part of our expanding Sierra Cosworth product range, AIRTEC Motorsport is proud to launch our intercooler upgrade suitable for track or fast road use.

This full size RS500-style intercooler is suitable for the 3-door Sierra as well as the 2wd and 4wd Sapphire Cosworths, with the 60mm core ideal for all models up to Stage 3 (400bhp) cars.

In order to ensure there is no noticeable loss in performance during extended periods of hard driving, we have developed a larger, freer-flowing intercooler that is a direct replacement for the smaller and more restrictive OEM item.

Our solution to increasing the intercooler’s size and performance within the confines of the limited space behind the bumper is based upon a high flow, single pass core with a huge 60mm depth. This offers a massive increase in overall capacity in comparison to the original intercooler, as well as a significant increase in frontal area over standard, which allows it to make the most of the air flow provided.

Together with our high-flow, moulded one-piece cast end tanks to ensure flow is directed correctly and efficiently, the AIRTEC Motorsport intercooler offers much greater efficiency and volume over standard.

The kit fits neatly behind the original bumper and can be reverted back to standard with no issues. It fits the original 60mm inlet and outlet pipes and the comprehensive fitting kit includes all the correct fixtures and fittings. The optional fitting kit includes uprated polyurethane mounting bushes to replace the soft rubber bushes usually used to reduce movement and flex.

The intercooler is available in a Pro-Series Black or Natural Silver (with or without the AIRTEC logo).

Voted ‘Best Buy’ by Fast Ford magazine ‘s intercooler test – issue 275

Standard intercooler:
Temperature in: 129.7 degrees
Temperature out: 49.5 degrees
Overall drop: 80.2 degrees

AIRTEC Motorsport intercooler:
Temperature in: 125.6 degrees
Temperature out: 22.1 degrees
Overall drop: 103.5 degrees


Width: 695mm
Height: 440mm
Depth: 60mm



  • 60mm thick track proven bar and plate core
  • AIRTEC cast end tanks for improved airflow and unbeatable strength
  • Fitting takes less 1-2 hours, comes with fitting instructions
  • 3-year unlimited mileage warranty
  • Available in Pro-Series Satin Black or Natural Silver
  • AIRTEC logo available at no extra charge


Please note: This will NOT fit the Escort Cosworth – please see here for our equivalent model AIRTEC Motorsport 62mm Core RS500-Style Intercooler Upgrade for Escort Cosworth – AIRTEC Motorsport



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