R56 MINI Cooper S - Install Forge Intercooler FMIC 2007-2013

Note: headlights don't need to come off for this job. Oops! How to install a Forge front-mount performance intercooler on a 2nd generation MINI Cooper S - turbo hardtop and convertible MINI Coopers and MINI Clubmans. Get the tools and parts here:
Forge intercooler: ebay.us/6z76aq
Turbo intake muffler delete: bit.ly/2ZIkvp9
GP2 Belly pan: ebay.us/3lJPGe
Body clip tools: amzn.to/2GQHEOA & amzn.to/2XQ9PD5
Body clips: amzn.to/2DD1NWx & amzn.to/2DDaM9U & amzn.to/2J3CZKz
Bent nose plier: amzn.to/2XNK7yQ
Milwaukee Jab Saw: amzn.to/2IOYkbo
Mod MINIs Gen 2 MINI Cooper parts and tools: amzn.to/2INHFFq

[@TheAutomotiveFanatic]

Thanks for putting this together. This will come in handy when I upgrade my Countryman's IC.

[@bubbaloo974]

I just have to say, you have saved me more times than I can list. Your like having the old chilton book of mini. I’m rebuilding a 06 JCW competition package (Canada only) number 39 of 64 built and there is always a little something to help that either would have cost a tonne of time or never figured out. Thank you thank you. Mine will get tracked at Mosport when it’s done as thats my home track.

[@DoktrDub]

There’s some handy tips in here! Good video, I ran into all sorts of walls with mine being a few years old, a few seized rusted bolts and what not, made it more stressful than it needed to be, especially working off the floor with axle stands, it was a pain lol

[@christopherdudley1585]

thanks mate, narrating is very helpful. please keep up the good work

[@wylinout2257]

Great information! Well done M8, thank you! 👍

[@gsxrpitguy]

Love your work! Wished you lived locally to me. I have 4 mini coopers in my household. I'm on my second JCW- I unfortunately totalled my last JCW 3 door clubman. I now have a JCW Paceman. The hardest of all the JCW to get.

[@dougmasters3875]

Holy crap, that's a lot more work than the pre-facelift cars!!!! Thanks for sharing, I would have been totally baffled by the differences. I was leaning towards a cheap intercooler, but that sounds like a nightmare on the 2011+ cars!!!

[@ModMINI]

You're only going to do it once... takes a half day

[@roberthelcher2884]

That was a great tutorial. Thank you for your amazing content.

[@tm5346]

Always excellent video’s

[@birgitc313]

That car is really like a Lego set :D i love it

[@theartofwanderlust]

Digging the new intro

[@steezymiyagi]

this video was so informative I think they can replace my dad no issue

[@benwickenden493]

those damn little groove thingys. Thanks for the great video

[@melraine919]

Nice One Mod MINI well done! UK

[@Eximplar]

Still a good video 😀

[@minimanadam]

Ha , I will be putting one on my r59 jcw today !

[@yerelcaceres7039]

Can you do a video on a 2004 mini Cooper s mod from a top Inter cooler to a front mount one if possible?

[@billgrattan5306]

How much are they the front mount in that little black thing for the turbo hose how much a wall up

[@slyrhythm6471]

Thank you sir!!!!!

[@billyhou9305]

Is there any noticeable difference in the engine temperature after swapping the intercooler, and do you have the new purchase link to the intercooler?

[@uyghurofficial7920]

I wil buy mini one 1.4 petrol 2007 or 2008,2009,2010 what you think about Mini?

[@Lauren-oc8hm]

Is this good to do if you’ve had a stage 1 tune won’t notice lag - I’ve heard you actually get better throttle response !?

[@gpzjeffrey7974]

I'm wondering, for anyone who's done this and driven in the hot summer, have you noticed any change in the performance of the air conditioning? This new intercooler partially obstructs the AC condenser, and the air going through the intercooler first is now hotter than before, which decreases the heat transfer rate on the condensor, and ultimately some to the radiator too that's sitting behind them both.

[@davebromwich5359]

Awesome video as always...can I ask what the intake muffler delete adds to this mod? I was thinking of upgrading my intercooler, so wondering if I should do that at the same time too.

[@ModMINI]

Slightly better throttle response.

[@erjones2222]

What kind of lift are you using?

[@musicsnob4226]

Why would you not upgrade the intercooler hoses and the radiator core if you're going to make that kind of a modification?

[@franky8330]

Hi I am a big fan of mini’s but i was wondering wich year I should take if I want a mini cooper s manual? Maybe if you could do a video of it. Thanks

[@ModMINI]

There is no one best answer. Depends on your budget and needs. 1st Gen 2005 or 2006 have a little better build quality, 2nd Gen 2011 or later are more reliable.

[@DollaSignSpadez]

heyy @modmini how much do you charge to make a video replacing vacuum lines A&B into the intake on 2005 MCS please!!!!!

[@ModMINI]

I don't make videos on demand.

[@geoffclement6138]

I need to do this for my Gen2 but a 2008 JCW. Do you really need to take out all the lights, bonnet release etc, I have seen some other videos where they don’t. Great video as always! 🤙🏼

[@malp6280]

for the 2008 it depends on the centre bracket ie if you use it or not etc (as shown) other then that no the crash bar isn't in the way of fitment as the crash bar is a lot smaller then this model shown you can also save money by buying cheaper versions of the same cooler forge/airtec are pretty much the most expensive. if your wanting to delete the charge muffler then again you can just remove the coolant bottle to gain access & a simple length of stainless intercooler tube at the correct dia the length required is something like 150-200mm

[@ModMINI]

See description. Headlights can stay on. I got carried away. Every time I've had to take bumper off on one of these cars I've also had to do headlights and upper crash bar but not needed for just the intercooler.

[@Cbarrocamo]

Hi mod mini, what are your thoughts on the sprintex super charger for the r53 ?

[@ModMINI]

This video has nothing to do with gen1 cars and I have no firsthand experience about that supercharger but I’ve heard it’s junk

[@ModMINI]

How to install a Forge front-mount performance intercooler on a 2nd generation MINI Cooper S - good for all turbo hardtop and convertible R55-R59 MINI Coopers and MINI Clubmans. Get the tools and parts here: Forge intercooler: ebay.to/2PzHSMH Turbo intake muffler delete: bit.ly/2ZIkvp9 Body clip tools: amzn.to/2GQHEOA & amzn.to/2XQ9PD5 Body clips: amzn.to/2DD1NWx & amzn.to/2DDaM9U & amzn.to/2J3CZKz Bent nose plier: amzn.to/2XNK7yQ Milwaukee Jab Saw amzn.to/2IOYkbo Mod MINIs Gen 2 MINI Cooper parts and tools: amzn.to/2INHFFq

[@22rjrobertson]

Swapped out my intercooler using this video the whole time! Thank you. Quick question. Did you get a positive crankcase fault? I’ve had this code before and got it “fixed” by the BMW dealership, but it’s back after the swap.

[@ModMINI]

I have not heard about people having codes just from replacing an intercooler, as long as the air path is properly sealed up

[@22rjrobertson]

Thanks for the reply. Something is going on and I don’t think it’s the intercooler.

[@dawidos32b]

@@22rjrobertson check lambda sensor :)

[@rogerwang0523]

dear sir, is there any turbo lag issue after a bigger intercooler is installed for R56? need any tunning for it?

[@ModMINI]

Some slight lag is likely. Don't need a tune to use, but need it to get all benefit of a tune.

[@denniscanon1558]

What lubricant are you spraying in the hose to remove them easily?

[@ModMINI]

Anything would work but I'll spray silicone spray which is nice because it doesn't leave behind a mess and sort of goes away on its own .

[@justiceotto8049]

Where u from

[@cocoloco902]

Are their any other cheaper reliable intercoolers??

[@ModMINI]

Check eBay - some may not fit as nice. rover.ebay.com/rover/1/711-53200-19255-0/1?ff3=4&toolid=11800&pub=5575439829&campid=5338396586&mpre=https%3A%2F%2Fwww.ebay.com%2Fsch%2Fi.html%3F_from%3DR40%26_trksid%3Dm570.l1313%26_nkw%3D2006%2Bmini%2Bcooper%2Bintercooler%26_sacat%3D0

[@Ryukushin]

I picked up my r56 JCW in 2013-2014, I can tell you one fact, but any clamp from the OEM (the ones that have that little hook) has in some way caused a vacuum leak, causing boost loss. Replace them, they're just a bad design and cheap to replace.

[@zapalskic]

How do you like your GP vs your sick old R53?

[@ModMINI]

I like the GP2 low RPM torque and overall smoothness/easiness to drive really fast (the breaks are excellent), but I miss the more direct feel of the and the sounds of the R53. I absolutely do not miss the R53 brakes or the notchy shifter.

[@leroyr5334]

🦄🦄🦄

[@jeelu666]

hi my r58 is throwing error 9E2E szl (steering column switch cluster):MFL(multi function steering wheel)-device status time out. cruise control and all the buttons are working on rhs cluster, lights wipers auto headlights everything working no dsc or airbag lights, just radio controls on LHS not working, also volume up and down not working. please help

[@bigjoetheelectrician]

That damn inner coolers for the r53 is $500 that made me sick

[@ModMINI]

It makes a difference. Check out the price of the intercooler on the GP1 if you really want to see a big price

[@brassmonkeegaming8583]

I picked up a gplus (Wagner replicer) for £40 (About $60 ) on ebay bids. The Gplus are fantastic, better then airtec (not sure on Forge, as I havent seen any data from them) but the Gplus kept the inlet temps down 12degrees over stock and temp change after a long drive, the charge air cooled down twice as fast. not bad for £40

[@Speedwelltuning]

Great video, thanks. My only criticism is that you tend to get rough and rip things out or out of the way, I’m pretty sure you scratched just under the front grill. I would be sacked if I treated the cars I work on like that, use a little more care.

[@burtzz]

Nice video, but if you want a proper intercooler buy a Wagner or airtec. Running forge ic or stock is pratically the same

[@malp6280]

the forge & airtec are basically identical & both are rougthly twice as large as the standard cooler...

[@ModMINI]

? Stock intercoooler is less than half the volume and cooling efficiency of the one I install here.

[@burtzz]

Mod MINI Size isn’t everything. Build quality, materials, internals, build architecture chosen, are also very important. I know a tune garage that tested all IC brands (r56) that matter on the market and the results were pretty obvious. Intake temp on the forge IC was almost identical to stock. Even a Chinese ic from eBay managed to do better intake temps. Best one, Wagner, followed by airtec revision2. Airtec ver1 isn’t great at all. PS: no idea if revision versions exist on the forge ic tbh

[@malp6280]

@@burtzz well I'd be sceptical regarding these claims further more was the forge unit a stock replacement cooler or the larger front mount cooler (you've not mentioned which model) you've also mentioned this tuning garage apparently tested all front mount coolers "that matter!" however you've then mentioned they've tested cheap ebay items (do these cheaper alternatives really hold up against direct reputable manufacturers products???) I'd also question how its possible to have a larger surface area cooler producing identical or near as it I/T temps as a standard item, especially if air flow was passing through it during testing. anyway forge items are usually very highly rated & have excellent build quality, the main problem is the costs

[@jrh1704]

@@malp6280 Nuno doesn't know what he is talking about

[@Eximplar]

Those headlights run from $1800 - $2300.00 for the bi-xenon, if there the active tracking ones the 2300$ before tax for the pair ... Better care should have been taken with the headlights and oem bi xenon bulbs for those are $250 each.

[@ModMINI]

In what way? I handle them the same for dozens and dozens of cars and zero issues

[@Eximplar]

Rough concrete floor vs a simple piece of cardboard. Hindsight is 20/20

[@jrh1704]

@@Eximplar He set it on the floor. You have to be joking

[@Eximplar]

@@jrh1704 and that's your opinion and I respect that no argument

[@meddlok]

@@Eximplar I hate people like you.