Performance intercooler for Hyundai I30 N-Line 1.4 T-GDi

Whether your Hyundai is completely stock or fitted with performance software, improved intercooling delivers immediate benefits. For modified vehicles, the increased cooling efficiency supports higher boost pressures and more advanced ignition timing, allowing you to safely extract additional performance without compromising engine reliability.

During our extensive testing, we allowed the car to heat-soak on the dyno until the radiator fans cycled on and off, resulting in an inlet temperature of approximately 33°C. We then carried out a dyno pull from this point, as it provides more consistent results and better reflects real-world driving conditions.

The results clearly showed that the Forge intercooler has far greater and consistent cooling capabilities and achieved a much greater reduction in intake temperatures compared to the OEM intercooler.

After multiple dyno runs, intake air temperatures (IATs) remained safely under control, with the Forge Motorsport intercooler recording temperatures as low as 24°C — almost half the factory intercooler’s 45°C result. These tests were conducted in relatively cool conditions, with an ambient dyno cell temperature of just 14°C, further highlighting the inefficiency of the stock intercooler.

In warmer climates, the limitations of the factory intercooler become even more apparent. Higher inlet air temperatures can significantly reduce engine performance, as the ECU retards ignition timing to prevent detonation. This results in noticeable power loss as temperatures rise. On mapped or tuned vehicles, the effects can be even more severe, potentially contributing to premature engine wear over time.

Design and Materials

Using a combination of advanced 3D scanning technology and traditional precision measuring methods, Forge Motorsport developed an exact digital model of the vehicle to ensure a perfect fit and optimal performance. This initial design was then extensively refined by our Computational Fluid Dynamics (CFD) engineering team, allowing us to optimise the end tank geometry for maximum airflow efficiency.

The bar-and-plate construction was selected for its exceptional strength and superior thermal mass when compared to traditional tube-and-fin designs, making it ideally suited for high-boost and high-temperature operating environments. The stepped-core layout further enhances airflow distribution and heat dissipation while maintaining excellent pressure efficiency.

The Forge design team has extracted the maximum possible performance gains without requiring any vehicle modification, ensuring FMINT40 remains a true plug-and-play solution. At the heart of the system is a high-performance stepped bar-and-plate intercooler core, delivering over 154% increased internal volume and an 133% increase in frontal surface area compared to the factory unit.

Technical details

• Weight: 8.5KG
• Core Dimensions: H 240mm, L 602mm, W 125mm (stepped)
• End box material: Sheet folded and TIG welded Aluminium
• Coating: Anti-corrosion coating with Anti heat-conducting properties
• Intercooler volume: 12.0 Liters
• Increase of size compared to OE intercooler : 153% volume :133%
• Fit: 100% Plug & Play

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