Front Mount Intercooler Kit (suits Toyota N80 Hilux 2016+)

Process West introduces a groundbreaking addition to its 4x4 Enhancement range: the TERRATUFF Front Mount Intercooler system, specifically designed for the N80 Hilux. This system is not just about leading the market in performance; it's built to last with OEM-level durability. It features a design that perfectly aligns with manufacturer standards and is supported by thorough testing and validation, ensuring top-tier quality and fit.

Installing the Process West TERRATUFF Intercooler system in your N80 Hilux signals a decision to equip your vehicle with the finest in charge air cooling technology, yielding substantial gains in power and torque. This choice reflects a commitment to enduring quality and performance, in line with the Process West TERRATUFF philosophy.

N80 Hilux TERRATUFF Design and Components:

The cornerstone of the Process West TERRATUFF Intercooler system is its robust, front-mounted Bar and Plate intercooler core. This construction is chosen for its superior cooling and heat-sink capabilities, along with its unparalleled durability and impact resistance. The N80 Hilux TERRATUFF core, measuring 590mm x 230mm x 78mm, significantly expands the cooling surface area and thickness.

The TERRATUFF system addresses the common challenge of piping integrity in intercooler upgrades. It features custom-designed, four-ply silicone hoses, combined with high-strength, constant tension hose-clamps and mandrel-bent aluminium pipework. This composition results in a product that is comparable to factory standards in both quality and reliability.

A crucial element of the TERRATUFF design is the inclusion of isometric rubber mounts for the intercooler core. These mounts allow the intercooler to flex along with the vehicle under extreme conditions, such as intense off-road use, reducing stress on the mountings and pipework. This design significantly lowers the risk of cracked mounting brackets and hose connection failures.

The Process West TERRATUFF intercooler system is a testament to serious, long-term application and performance.

N80 Hilux TERRATUFF Testing Methodology:

Process West's engineers have moved beyond conventional dyno testing, which may not fully represent real-world conditions. Instead, they have developed a practical, real-world simulation to validate the TERRATUFF design:

• Loading an N80 Hilux with 650kg of concrete blocks.
• Conducting a 4km uphill run with a 310m elevation gain.
• Maintaining a speed of 80km/h using Cruise Control.
• Employing a sophisticated AIM data-logging system to capture comprehensive cooling data.

This testing, performed with both the standard and Process West TERRATUFF intercoolers under identical conditions, revealed significant improvements. The factory intercooler peaked at 39C, while the TERRATUFF system only reached 24C, demonstrating a 38% increase in cooling efficiency. This improvement leads to noticeable gains in torque and power and contributes to lower EGT figures, promoting a longer and healthier engine life.

Summary:

The Process West TERRATUFF Intercooler system distinguishes itself in the market through its detailed design, development, and testing process. Its efficiency and durability have been proven in real-world conditions, making it ideal for demanding off-road activities or towing across Australia. Choose Process West TERRATUFF for unmatched reliability and performance.