2006-2015 Mini Cooper S Intercooler Upgrade | Forge

For the 2007 onwards models* Second generation (R55/R56/R57/R58/R59) BMW Mini Cooper S Turbo we have developed a more efficient intercooler. As a reduction in intake air temperature increases the density of the charge mixture within the combustion cylinder any temperature reductions will equate to more power. This intercooler is constructed using a combined 80/40mm high thermal efficiency core, with a 250% larger surface area and a 125% thicker base core, to achieve the best possible results.

As you can see from the graph, Forge has achieved a significant reduction in temperature.

In fact even in relatively low road speeds / air velocities our intercooler was able to better the OEM unit by nine degrees centigrade, with greater improvements being achievable during greater speeds during track testing. The replacement intercooler is supplied with all the mountings and a replacement lower grill to allow ease of installation. Please note that this kit has been designed to fit behind the original Cooper S front bumper, and to that end we supply an original BMW Mini grille which can be inserted into your bumper allowing clearance for the intercooler. If an alternative aftermarket front bumper has been installed, e.g. the JCW front bumper, our intercooler will still fit, but the grille will have to be modified by the customer.