Forge Motorsport intercooler for Hyundai Kona N

Key features:

• power increase of approx. 21 hp
• torque increase of approx. 28 Nm
• 27% larger volume than the factory cooler
• bar-and-plate core construction
• Designed and manufactured in Great Britain

The Hyundai Kona N differs significantly from the i30N in the crash bar, and testing has shown that the stepped design for the Kona N does not work as well as it does on the i30N. During development, a metal model of the cooler was used to optimise airflow. Using hand-shaped sheets and brackets, it was possible to fit an 83% larger intercooler in the original position. The front surface area of the cooler has increased by 27% compared to the original cooler, without affecting the cooling of other vehicle components. The intercooler also includes vanes that direct air to the active surface of the cooler.

The intercooler inlet and outlet have been increased to 65 mm, which means a cross-sectional increase of 27% compared to the factory part. The intercooler kit also includes a hard pipe with a diameter increased to 64 mm from the factory 50 mm for maximum cooler performance. The cooler and pipe are supplied in black textured paint for a subtle look and long service life. For maximum efficiency, we recommend adding a boost pipe to the cold side of the cooler (code FMBP7).

With the use of the i30N engine with a different turbocharger setting with higher boost pressure, the use of a more powerful intercooler is even more necessary than with the i30N. The vehicle on which the Forge Motorsport intercooler was tested already had a Stage 1 ECU remap and a Forge Motorsport sports intake (FMINDK28) installed, along with a turbocharger inlet (FMTIA10). After several pulls, the car gradually began to lose power due to the high intake air temperature. On the third attempt, the vehicle measured 348.3 hp and 459 Nm of torque.

Installation of the Forge Motorsport intercooler brought a significant change in the resulting power, and the intercooler kept the intake air temperature around 27°C. An increase in power of 21 hp and torque of 28 Nm was measured. Most of the increase in torque was measurable from 3000 rpm.

Even after six measurements, the intake air temperature remained at a safe value of 27°C with the Forge Motorsport intercooler, while the factory intercooler was significantly behind with a temperature of 48°C. Testing took place at a relatively low ambient temperature of 20°C. A more significant difference can be expected in hot summer months.

Installation time is approximately 3 hours, depending on experience and available equipment. The Forge Motorsport intercooler is a direct replacement for the factory intercooler. The only modification required is to cut off the sensor bracket and then apply anti-corrosion paint.