Forge Motorsport uprated intercooler for Nissan Juke

Gloucestershire-based Forge Motorsport may be better known for its race-quality componentry for the more fire-breathing cars in Nissan’s line-up, like the R35 GT-R, but it hasn’t stopped the respected engineering outfit creating similarly sublime components for the somewhat more attainable DIG-T Juke. The latest of many components in the pipeline is a race-quality intercooler for the 1.6 turbo engine.

Forge’s design team began by looking at how to improve airflow through the intercooler to achieve maximum efficiency. After highlighting several compromises with the original design, the team started from scratch, using larger pipework, custom formed silicone hoses and a complete re-design of the intercooler’s end tanks. All of these proved in testing to lower the temperature of the charge air when compared to the standard part.

After analysing locations for the new part, repeated dyno tests revealed that the factory had got the position spot on. With the decision made to utilise the stock location, but to significantly increase core size, a very careful and clever bit of packaging had to be carried out to allow the new Forge part to install precisely on the OEM mountings and fit subtly behind the stock bumpers, without any obvious external modification. Not only is the new ‘cooler much larger than the part it replaces, it also utilises a much more efficient type of intercooler core that offers yet more thermal efficiency.

Under testing, the Forge unit managed an incredible reduction in intake temperature of up to 20° centigrade which, combined with reduced pressure-loss, allows the engine to produce more power and torque throughout the rev range. As cooler engines also tend to last much longer, the part has a practical application to add to its performance credentials.

This upgraded intercooler has been designed to work perfectly on any standard Juke, and is ideal for vehicles that are used for towing or will be further tuned at a later date. In fact, when tested on a car running Litchfield Stage 2 ECU software, there was an additional gain of 15+ bhp after installing the intercooler, proving how well it works in conjunction with other modifications.

The unit is priced at £499.00 + VAT.

For more information, visit forgemotorsport.co.uk.