Front Mount Intercooler Kit - Isuzu D-Max (07/2012-07/2020)

New in the Process West 4x4 Enhancement range is the Terra-Tuff Front Mount Intercooler system for the Isuzu DMAX.

Designed not only with market leading performance in mind, OEM level durability is also part of the Terra-Tuff arsenal, offering manufacturer style design and fitment, followed through with industry leading testing and validation. Notably this intercooler kit will fit all models of DMAX from 07/2012 onwards including the DPF models. This means that when you fit a Process West Terra-Tuff Intercooler system to your Isuzu DMAX you have made a choice to have not only the best charge air cooling, resulting in significant power and torque gains, but you have also chosen a product that will last the life of your vehicle no matter what you throw at it. That’s the Process West Terra-Tuff way!

Specs:

• Intercooler core size 673 x 200 x 80mm
• High flow cast aluminium end tanks

Kit Contains:

• The Isuzu DMAX Terra-Tuff intercooler kits comes with the intercooler core and a pair of replacement front silicone intercooler hoses, which is all of the parts that sit behind the grille of the vehicles. This means that fitment is incredibly simple requiring only the grille to be removed and the intercooler and piping bolted straight in. 

Suits:

• Isuzu D-Max (07/2012-07/2020)

Optional:

• Available at additional charge the optional silicon piping kits can be ordered for those that want to replace all of the factory hoses with Process West Terra-Tuff parts then there are two different options to suit both DPF and non-DPF models.

• All Process West Terra-Tuff specifically moulded silicone hoses are of four ply construction combined with high-durability constant tension hose-clamps.

ISUZU D-MAX TERRATUFF Design Philosophy and Parts

Heart of the Process West Terra-Tuff Intercooler system is a durable front mounted Bar and Plate intercooler core. All Terra-Tuff intercoolers use Bar and Plate construction due to not only its effective cooling and heat-sink capability, but also because it is the most durable and impact resistant of all intercooler types. This is a huge replacement intercooler core measuring 673 x 200 x 80mm giving a massive increase in cooling surface area as well as overall thickness when compared to original.

ISUZU D-MAX TERRATUFF Testing

There is no point in putting a vehicle on the dyno to try and show the effects of intercooling on performance. While there might be a little torque or power gain, the job of the TERRATUFF intercooler upgrade is to work in real-world conditions without the assistance of a climate controlled dyno room and the cooler itself fed with artificial airflow from a fan. This might convince some to buy intercooler upgrades, but it doesn’t really tell you how, or even if, they work.

Instead the Process West engineers took a different approach to validate the TERRATUFF design. Real world simulation rather than a dyno run was decided on, and with that in mind the team put together a test rig for our development Ranger to show the precise and measured result of fitting a Process West TERRATUFF intercooler upgrade. The schedule for this testing is laid out below –

• The Isuzu D-Max is loaded with 650kg of concrete blocks in the tray
• A standardised 4km uphill run with an elevation of 310m (nearly 8% avg grade)
• Hold 80km/h road speed using Cruise Control (with only a small traffic speed variance)
• Use our racetrack developed AIM datalogging system to measure all of the pertinent data points to ensure the data for complete cooling effectiveness is generated.
• This test procedure was carried out back to back with both factory and Process West TERRATUFF intercoolers on the same day in the same ambient conditions.