I decided to do somewhat of a write-up and provide feedback and input from my experience of my recently installed Forge Intercooler on my 2021 F60S. Reason being, I wasn't able to find much information that was already posted for the LCI S models and I'm hoping this will help someone else that might have the idea of upgrading their intercooler as well. The goal behind the upgrade is to prepare the vehicle for a Dervtech tune in the future just as I did with my R56 JCW. Upgrading the intercooler opens up more options for a tune beyond Stage 1.

When I started this journey, I knew there would be challenges with finding the right intercooler that would fit the 2021 Countryman S. Understanding that most performance parts are designed for the F56 or the F60 JCW models, fitment was a concern because the F60 Countryman is slightly different around the engine bay, but also the revision that occurred with the 2020 LCI refresh. After numerous research and having the chance to talk to other members of the MINI community, Forge USA and the good team at Dervtech UK, I found that the best option was the Forge FMINT8. The other option that I had in mind was the Wagner intercooler. I wasn't too familiar with their tube and fin design since I've always used the bar and plate design on my previous intercooler upgrades but I've read good reviews regarding the cooling properties of that design. However, after having the chance to reach out to Wagner and also speak with another MINI community member, I found that the Wagner does not fit the LCI models. Reason being is that the housing of the intercooler has certain angles that prevent the radiator from seating properly. Therefore, my my only option was the Forge FMINT8 model which was designed to replace the 7 core OEM intercooler that MINI started to install in the S models with the LCI refresh. Not sure why MINI went from the 11 core to the 7 core intercooler version from the factory on the S models but living in such a hot climate was not ideal for one who has the ambition to enhance the car's performance.

The journey did not start off as easily as I had hoped. I've kept my eye on the intercooler being sold by different vendors such as ECS and UroTuning and jumped at the moment it went on sale with ECS. Unfortunately, when that intercooler arrived in the mail, the box looked like it went to hell and back and my worries were concerned as soon as I opened the box and found the intercooler to be damaged. The bottom plate was severely dented in different places and the fins were crushed in those areas. Thankfully, ECS Tuning allowed me to return the intercooler for a refund but I had to wait again since this model was on backorder. Trying to get an idea of when the next shipment would arrive from the UK, I called Forge Motorsport USA directly and they were more than helpful to assist me in placing a new order directly with them and even provided another discount on top of the sale with a detailed timeline of when it would arrive and ship approx 3-4 weeks later.

The new intercooler arrived and I was excited and anxious to start the install. The first obstacle was trying to identify how to remove the bumper on the F60 Countryman. The instructions that are provided by Forge and other videos I found on Youtube focus on the F56 models but using those instructions, I was able to work my way around and remove it with little to no problems. Honestly the hardest part of that was holding the bumper with one hand while unclipping the wires from the body and the fog lights. I used a parts divider tray to store and organize the hardware as I removed it and labeled it accordingly to assist me when putting it all back together.

The removal of the OEM intercooler was seamless with no issues but the challenges started to present themselves as I installed the new intercooler. The first then that came to my attention is that the radiator mounting pegs do not fully seat in the wedge tabs of the new intercooler. I double checked to ensure the slots on the backside of the radiator fully seated on the holding points of the intercooler but then discovered that the bottom of the radiator has a foam padding and there's also points on the radiator that are lower than the foam padding that make direct contact with the intercooler. Realizing I would need to leave a gap in the tab wedges and use spacers, my plan was to use 1/4" rubber durometer pads in that void on each side where the radiator mounting points would seat to keep the radiator from making contact with the intercooler. Because I used spacers, I would then need to procure longer screws that secures the radiator to the intercooler. I would have had to get different screws regardless because the replacement screws that come with the intercooler are not the same design as the OEM screw. Forge provides an M6 metric screw but the OEM screw is a self tapping coarse metal screw designed to thread itself into the plastic housing of the radiator. So essentially I had to make a hardware run store for the longer screws and while I was there I found Green Egg High Temp Felt Strips and placed it on top of the intercooler where the radiator would make contact for added protection between the units. This is the felt strip padding that goes on the inside of the grill where the lid makes contact with the bottom. Who would've ever thought....

The next challenge to overcome was how to properly route the hose for the auxiliary radiator with the new Forge intercooler. Since the OEM intercooler is much shorter in design, the hose was able to be routed over the top with no tension on the fittings of the main or aux radiator. Unfortunately, due to the design of the Forge being taller, the hose cannot be routed over the top as it puts tension on the main radiator plastic fitting. The best course of action was to route it in front of the intercooler and then double wrap the hose in silicone tape in the area it makes contact with the intercooler to cushion it and prevent abrasion.

Although the installation took longer than expected due to the obstacles to overcome, I'm still impressed with the build quality and the level of customer support Forge provides. After everything was put back together, I started the car and let it run in the garage for 10-15 minutes just to see if anything was abnormal. I was specifically looking to see if the hose being tight against the intercooler was going to be a problem and checked to see if that fitting was damaged. I didn't expect it to be even though it's tight. But honestly there's a bit of play which lowers my concern. Worst case scenario, if I ever think it will be a problem in the future, I'll find a way to delete the auxiliary radiator with hopes that the main radiator will provide sufficient cooling properties. Not sure if the Pre-LCI models have the same aux radiator or a different main radiator.

My first initial drive, I noticed a slight loss in boost psi but that was expected. With the large intercooler and the increased volume 1.5 psi loss is not something I'm concerned about because with the tune and increased boost levels, it will be increased. Today's weather is a drizzly 60 degrees with misty rain so I'm not able to really get an idea of the lower temperature readings I should be expecting . Later in the week it's warming backt to 80 degrees and of course this summer we'll see 100+ degree ambient temps where I'm certain this larger intercooler would be very beneficial.

I've included pictures that I took during the install to help explain what I experienced. Hope this helps and if anyone has the idea of doing the same and has questions, please don't hesitate to reach out.

***for those wondering about the lift, that's the QuickJack 7000. That the lowest setting in the picture and the height was perfect for this job. Definitely makes it easy to work on all our vehicles to include my truck easily***