Forge Motorsport intercooler for Hyundai Kona N

Key benefits:

• Up to 21 hp gain
• 28 Nm torque gain
• 83% greater volume compared with the original intercooler
• Bar-and-plate construction

Following the success of our performance upgrades for the Hyundai i30 N MK3 and Veloster N, we have developed an upgraded intercooler for the Hyundai Kona N. Due to the different design of the bumper mount and the results of extensive testing, it became clear that a stepped core is not the most effective solution for the Kona N. This design would also not allow fully reversible, direct-replacement installation.

During development, our engineers used their knowledge and experience in sheet-metal fabrication to hand-form the aluminium sheet and the necessary mounts. This made it possible to install an intercooler with 83% greater volume in the original position and improve airflow through the bar-and-plate core. This is the ideal installation, as the frontal area increases by more than 27% without negatively affecting the vehicle’s other cooling components. The development team also produced a hand-built air ducting system, carefully integrated into the design to ensure that as much air as possible passes through the intercooler surface.

The inlet and outlet diameter has been increased to 64 mm, providing 27% greater volume compared with the original intercooler charge path and therefore improved flow. The kit also includes a special 64 mm hard pipe, compared with the factory 50 mm pipe. This replaces the original hot-side pipe and ensures adequate flow even on highly tuned engines.

The charge pipe and intercooler are protected with a standard black textured powder coat.

For even better flow on the cold side, the Forge Motorsport FMBP7 charge pipe can be added.

Dyno testing

The Hyundai Kona N uses the engine from the i30 N MK3.5, in which the turbocharger was newly developed for higher boost pressure and greater flow than in the previous generation. Replacing the restrictive original intercooler with a larger Forge Motorsport unit therefore makes particular sense.

The development vehicle had a Courtney Sport ECU Stage 1 tune, together with a Forge Motorsport FMINDK28 intake system and FMTIA10 turbo intake hose adapter. Results before installing the Forge Motorsport intercooler were still impressive with the original intercooler, but after several consecutive runs the tuned engine began to struggle to maintain low intake air temperatures.

During extensive testing, we left the vehicle on the dyno to heat-soak until the radiator fans were cycling on and off. At that point, the intake air temperature was approximately 40 °C, followed by a test run. This procedure provides more comparable results and more accurately replicates conditions encountered during everyday driving.

The tests were carried out by Performance Remap in Gloucester on a VTEC four-wheel-drive dyno, allowing an independent tuner to provide the most accurate results possible. During the third run, when the intake air temperature began to rise, the measured output was 348.3 hp and 459 Nm of torque.

Installing the Forge Motorsport intercooler significantly improved power output and maintained the intake air temperature at approximately 27 °C even after several consecutive runs. The maximum measured gain was 21 hp and 28 Nm of torque, with the improvement noticeable from 3000 rpm.

After more than six dyno runs, the intake air temperature still remained at a safe 27 °C, almost half the 48 °C measured with the original intercooler. Testing took place at a relatively low ambient temperature of 20 °C, further demonstrating the inefficiency of the standard intercooler. In summer conditions, the standard intercooler combined with a higher intake air temperature can have a significantly negative effect on engine performance. In such conditions, the engine management system will reduce ignition timing to prevent detonation, so engine power will decrease as temperatures rise. On a vehicle with modified software, the effects can be even more pronounced and may lead to premature engine wear.

This intercooler, combined with our intake system, a quality cat-back exhaust system and the original software, provides a very high level of performance.

The Forge Motorsport front-mounted intercooler includes all the required installation hardware. Installation takes approximately 3 hours, depending on the installer’s experience and the tools available.

Compatible additional products

• Charge pipes
• Oil cooler
• Turbo intake hose adapter

Suitable for: Hyundai Kona I (OS).