TERRATUFF by Process West Front Mount Intercooler Kit – Toyota HiLux (N80)

TERRATUFF by Process West Front Mount Intercooler Kit – Toyota HiLux (N80)

A fresh development in the Process West 4x4 Enhancement range, the TERRATUFF Front Mount Intercooler system for the N80 HiLux combines market-leading performance with OEM-level durability. Designed for the life of your vehicle, this system provides superior charge air cooling, resulting in significant power and torque gains regardless of the conditions.

The TERRATUFF philosophy focuses on real-world reliability. Featuring a heavy-duty front-mounted construction and isometric rubber mounts, the system is designed to flex with the vehicle during extreme off-road use, preventing cracked brackets and failed hose connections common with lesser upgrades.

Key Features

• High-Efficiency Core: Features a massive 590mm x 230mm x 78mm Bar and Plate core, offering a substantial increase in surface area and thickness for maximum heat-sink capability.
• Proven Temperature Reduction: Real-world testing with a 650kg load showed a 38% improvement in cooling, with peak temperatures dropping from 39°C (factory) to just 24°C (TERRATUFF).
• Durable Piping System: Utilises specifically moulded four-ply silicone hoses and mandrel-bent aluminium pipework secured by high-durability constant tension hose clamps.
• Isometric Rubber Mounts: Unique mounting system allows the intercooler to flex independently of the chassis, relieving strain on the unit and pipework during demanding off-road driving.
• Engine Longevity: Lower intake temperatures directly result in reduced Exhaust Gas Temperatures (EGTs), helping your engine live a longer, healthier life under load.

Real-World Validation

Unlike standard dyno testing with artificial airflow, Process West engineers validated the TERRATUFF design through rigorous uphill climb simulations under a 650kg load. This ensure the data reflects actual driving conditions, such as towing a caravan or navigating steep terrain in the Australian outback.

Specifications

• Core Dimensions: 590mm x 230mm x 78mm
• Core Type: Impact-resistant Bar and Plate
• Mounting: Stress-relieving isometric rubber mounts
• Hoses: Four-ply heavy-duty silicone
• Compatibility: Toyota HiLux N80 (2.8L Turbo Diesel)

What’s Included

• 1 x TERRATUFF Front Mount Intercooler Core
• Complete Mandrel-Bent Piping Kit
• High-Durability Silicone Joiners & Constant Tension Clamps
• All Required Mounting Brackets & Hardware