Product Overview
Highlights
- Temperature drops of up to 21°C
- Engine Code G4LD
- Direct replacement, plug and play fitment
- BHP gains of 5 BHP and 12 NM on standard software
- Greater overall surface area for greater heat dissipation
- High flow cast end tanks ensuring optimum air transition for cooling efficiency
- A smoother power curve
- Volumetric increase of more than 133%, without additional lag
- Frontal area increase of over 154%
- Lifetime warranty* (T&C’s Apply)
Forge Motorsport has a long and proven heritage in the development of high-performance components across the Hyundai N platforms. And with our experience supplying the Excelr8 Hyundai touring car team with cooling packages, we bring unparalleled knowledge, engineering expertise, and real-world motorsport experience to every product we design. This background allows us to consistently deliver some of the most advanced and performance-focused upgrades available for Hyundai vehicles.
FMINT40 is Forge Motorsport’s performance intercooler which features an enlarged stepped-core design which dramatically increases heat-transfer efficiency, allowing this cooler to dissipate heat more effectively from compressed intake air. Lower intake air temperatures result in denser air entering the engine, improving combustion efficiency and reducing the likelihood of detonation.
The result is stronger, more reliable power delivery, even during sustained high-load usage where stock intercoolers are prone to heat soak.
%20(14%20of%2015).jpg)
%20(7%20of%2015).jpg)
Development and Results
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.
%20(1).jpg)
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.
%20(6%20of%2011).jpg)
%20(5%20of%2011).jpg)
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
%20(8%20of%2011).jpg)
%20(4%20of%2011).jpg)
