Forge Motorsport intercooler for Hyundai Elantra N VII (CN7)

• 111% larger volume than the standard intercooler
• Up to 50% lower intake air temperatures (IAT)
• Improved torque and performance
• Replaces the original part 28270-2GT10
• Made in the United Kingdom

Forge Motorsport developed the upgraded intercooler for the Hyundai Elantra N with a bar-and-plate type core. During development, SolidWorks 3D modelling, computational fluid dynamics (CFD) simulations and experience from developing products for the Hyundai i30 N were used. The hand-fabricated, free-flowing end tanks are designed to fit the available space in the Elantra N chassis and improve airflow and cooling performance.

The core has 111% greater volume and a 58% larger frontal area than the standard cooler, making it one of the larger intercoolers for the Hyundai Elantra N. For more efficient airflow, a custom-made ducting system is also included. It is installed in the front bumper and directs air through the core.

The inlet and outlet connections have been increased to 65 mm, providing 27% greater flow volume than the factory version. The kit also includes custom-made silicone hoses for a tidy connection to the surrounding engine components. The intercooler is protected with a black textured powder coating.

After testing several core designs, the bar-and-plate configuration used in the Forge Motorsport intercoolers for the Audi RS3 and TTRS 8S was selected. The internal core design, fin shape and fin density are optimised for low pressure drop and efficient charge-air cooling.

Core selection and testing

During intercooler development, different core designs are tested, including bar-and-plate and tube-and-fin versions, as well as different fin spacings and heights, such as 22 or 17 fins per inch. By changing the internal spacing, shape and density of the fins, the pressure drop and cooling efficiency can be precisely adjusted.

Pressure drop is not always a bad thing, as slowing the flow of charge air can allow more time for it to cool. However, excessive pressure drop places greater strain on the turbocharger in higher-performance engines. This generates more heat, which can increase intake air temperature. On the other hand, zero pressure drop does not necessarily guarantee efficient cooling. The core configuration is therefore selected and tested for the specific application.

During dyno testing, intake air temperatures were reduced by half. The vehicle was warmed up on the dyno before the measurements, while the radiator fans switched on and off at an inlet temperature of approximately 40 °C. After six consecutive measurements, the Forge intercooler maintained an intake air temperature of just 24 °C, while the standard intercooler reached 48 °C. Testing was carried out at a controlled ambient temperature of 15 °C.

Higher intake air temperatures can reduce engine performance, as the ECU adjusts or retards the ignition to prevent detonation. The result is lower power and, in modified vehicles, greater engine load. The Forge intercooler provides more stable charge-air cooling during demanding driving.

Suitable for: Hyundai Elantra VII (CN7).

Compatible vehicles (manufacturer data)

Before ordering, check that the product matches your vehicle (model, year and engine). If in doubt, write to us — we will check for you.