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Description
Product Description
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.
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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.
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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.
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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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Complimentary Products
Click here to find out about information and care for your
Forge Motorsport cooling product.
Please Note: In line with our policy to constantly review, revise, and improve our product range, the appearance of the product you receive may differ from the one advertised.
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Compatible Vehicles
Instructions
Performance intercooler for Hyundai I30 N-Line 1.4 T-GDi
Warranty
Warranty Information
The majority of Forge Motorsport products come with a limited lifetime warranty. All warranty claims must be accompanied by the original proof of purchase to enable us to help you — failure to supply this proof will result in your claim or enquiry being denied. Please note that some products are excluded from the Forge lifetime warranty and instead carry their own specific warranty terms — for example, air filters, electrical components, coil packs, carbon fibre products, and suspension kits. This page is a summary only; a full and current list of exclusions, along with their specific warranty terms, can be found on our Terms & Conditions page.
For further information, please call our customer service team on +1 865 951 7456 or email sales@forgemotorsport.com
Do not use aggressive (acidic) car cleaning products, particularly traffic film remover solutions or shampoos, to clean your intercooler, radiator, or oil cooler. The use of these products can damage Forge Motorsport cooling systems and invalidate your warranty. These are often found at car washes. A light, warm, soapy solution (free of harsh acidic cleaning compounds) should be used to clean your cooler, and thoroughly rinsed away afterwards. We recommend that you inspect your product regularly for bent and/or crushed fins — any bent fins should be carefully straightened to allow ambient air to pass through the core face. At the time of installing your Forge radiator, an approved coolant must be used. Be sure you never mix coolant types, and always use distilled water.
This warranty does not apply to any defect in the goods arising from fair wear and tear, wilful damage, accident, negligence by you or any third party, use otherwise than as recommended by the supplier, failure to follow the supplier's instructions, or any alteration or repair carried out without the supplier's approval.
This does not affect your statutory rights.
Ignition Coil Packs
Forge ignition coil packs carry a 12 month warranty against manufacturing defects (not our Lifetime Warranty), from date of purchase. As coil packs are often swapped as a full set on suspicion rather than a confirmed fault, claims must identify the specific faulty unit(s) with supporting evidence (e.g. a diagnostic misfire code) and proof of purchase. Full sets cannot be claimed without this. See full terms and conditions for details.
Electrical Components
Electrical components supplied with Forge Motorsport kits — including solenoids, wiring harnesses and looms — are covered by a 12 month warranty against manufacturing defects, rather than our standard Lifetime Warranty. This covers faulty materials or workmanship only, and does not cover damage from incorrect installation, water ingress, wear, incorrect wiring, or faults originating from your vehicle's own electrical system or other aftermarket electrical accessories. Full terms, including how to make a claim, are available in our Terms & Conditions.
Heat Management Products (Turbo Blankets and Gold Reflective Heat Barrier)
Turbo blankets and our gold reflective heat barrier are covered by a 6 month warranty against manufacturing defects (not our Lifetime Warranty), from date of purchase. Turbo blankets cure and lose flexibility over their first few heat cycles as a normal part of fitting. Once heat-cycled they should not be removed. The gold reflective heat barrier is designed for components such as engine covers, intake pipes and induction trays, not for direct contact with exhausts or turbine housings. See Terms & Conditions for details.
Shipping
Shipping
USA Deliveries
All Deliveries are sent via Fedex. We cannot guarantee delivery timelines as all orders are up to shipper schedules and routes. Delivery fee is a Flat Rate of $20 fo all orders over $20. Orders below that value are costed out based on weight. Signature required may be added to your package. Orders can not be re-directed, held, or re-scheduled.
Shipping outside of the Lower 48- Duty Charge Information
All Forge products are sold with a Delivery Duty Unpaid (DDU) status and an import tariff may apply to your order. Customers will be contacted by the Customs and Excise authority in the destination country regarding payment prior to delivery, and it is important that correct contact telephone number and email information be submitted with the order to facilitate this part of the delivery process.
Our shipping methods ensure safe and timely delivery of your new Forge products. For further information on cost and delivery times, please contact Forge using the info@forgemotorsport.com email address if you require any more information. We reserve the right to change the delivery service and company at any time.
***Once a product has left our warehouse and is in the possession of the shipping company, any claims must be made directly with that shipper however we can assist with most cases.
