is here! Shop now, pay later in 4 easy instalments
An intercooler upgrade is one of those mods where the answer really is "it depends". On a tuned Patrol towing three tonnes through the Top End, it can be the difference between a relaxed engine and one that's pulling power to protect itself. On a stock ute doing the school run, you won't notice it's there.
Here's how to work out which of those you are.
What an intercooler does
A turbo compresses air, and compressing air heats it. Hot air is less dense, so it carries less oxygen into the cylinder, and it pushes combustion and exhaust temperatures up. The intercooler sits between the turbo and the engine and takes that heat out.
Cooler intake air means more oxygen for the same boost and lower exhaust gas temperatures. On a diesel, exhaust gas temperature is the number that matters for engine life under load.
Where factory intercoolers fall short
The factory unit is sized for the factory tune and an average load. Three things push it past that.
A tune
A remap adds boost and fuel. More boost means hotter air coming out of the turbo, and the standard core can't shed the extra heat fast enough.
Sustained load
Towing up a long grade or driving in soft sand holds the engine at high boost for minutes at a time. The intercooler heats up and stays hot. That's called heat soak, and once it sets in, intake temperatures keep climbing.
Top mount placement
Many older 4x4s have the intercooler on top of the engine, fed by a bonnet scoop. At highway speed it gets airflow. Crawling in low range or sitting in traffic, it's sitting in the hottest part of the engine bay with very little air moving through it.
Signs you'd benefit
- Exhaust gas temperatures that climb quickly under load and force you to back off.
- Intake air temperatures, read from a scan gauge, that sit well above ambient when towing.
- Power that fades on long hills or on hot days and comes back when things cool down.
- You've had the engine tuned, or you're about to.
If you don't have gauges for exhaust and intake temperature, fit those first. They'll tell you whether there's a problem to solve.
Top mount or front mount?
Upgrade kits come in both layouts.
A larger top mount keeps the factory position and plumbing short, which keeps throttle response sharp. Good kits add a bigger core and often a fan to pull air through at low speed.
A front mount moves the intercooler in front of the radiator, where it gets clean airflow whenever the vehicle is moving. It handles sustained load better. The pipework is longer, and it has to fit around bullbars and winches, so vehicle-specific kits are worth paying for.
What we stock
Our intercooler kits are mostly from High Performance Diesel, with close to a hundred fitments. They cover the Patrol GQ and GU (TD42, ZD30 and RD28), the Landcruiser 60, 70, 80, 100, 105 and 200 Series, the Hilux, Navara, D-Max, Triton, Ranger and more, in top mount and front mount versions where both suit.
A few examples: the 200 Series V8, the Navara NP300 front mount, the N80 Hilux and the GU Patrol ZD30 common rail. For the PX Ranger and BT-50 there's also the ATI performance intercooler in our intercooler upgrade range.
Do the cheap things first
Before spending on a core, check the parts either side of it. A split or swollen intercooler hose loses boost and makes the turbo work harder for the same result. Replacing tired hoses costs a fraction of an intercooler and fixes a problem you may already have. See why factory intercooler hoses split.
A catch can also helps here, because oil coating the inside of an intercooler reduces how well it transfers heat.
Common questions
Will a bigger intercooler add power?
On a stock tune, very little. Its job is to keep temperatures down so the engine can hold its power under load, and to give a tuner room to work safely.
Do I need a tune after fitting one?
No. A bolt-on intercooler works with the standard tune. If you're planning a remap, fit the intercooler first so the tuner can account for it.
Will it cause turbo lag?
A much larger core and longer pipes add a little volume for the turbo to fill. With a kit sized for the engine, most drivers don't notice it.
Is an intercooler upgrade legal?
Replacing the intercooler doesn't alter emissions equipment. Bonnet scoops and front-mounted hardware have their own rules about protrusions and airflow to the radiator, so check your state's requirements.
