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Hey Guys,

Can the 2.5L Hilux take an intercooler? Has anyone ever ventured into it? I'm not familiar with the engine makeup or layout of the 2.5 and the 3.0, but I believe the 3.0 has the top mounted intercooler.

Would it be as simple as getting a 3.0 intercooler and installing it, and either cutting the bonnet for the scoop or changing the bonnet?

Would this project cause any significant changes in performance of the vehicle?

No major downside to installing an intercooler.. the only thing you could do wrong is install one that is too large and it causes pressure drop. Purchase an intercooler similar in size to the factory one, a little bigger is ok as well, then find the most appropriate location, mount and plumb it in.

Top mounts are susceptible to heat soak and proper engineering will need to go into putting one there. A front mount is more practicable for the DIYer and easier to safely mount.

I can't say if it will cause a significant change in performance, but depending on the efficiency of the cooler, it will be of benefit. If you have a turbo charged vehicle, i will recommend installing an intercooler.

i asked A sales man why the 2.5 L doesn't have a inter cooler he said due to the smaller size ( 2.5 compared to the 3.0 ) engine the Firm ( NOT TOYOTA TRINIDAD ) said its not necessary and if u install one you will get the same or maybe less performance because its designed like that , he said also if u install one you will lose you warranty

I don't believe the intercooler from the 3.0 will fit directly on the 2.5 without some modification
The location of the turbos are different necessitating some work (its not as simple as just bolting it on and going)

BTW There are versions of the 2.5 with the intercooler being sold by toyota....just not locally. That model has around 16hp/65Nm more than the non-intercooled version

The newer model(2012) 2.5 is also now being eqipped with the same vnt turbo intercooler setup as the 3.0 (max torque is the same but Horsepower is around 145; its 167hp for the 3.0) Again.....NOT SOLD LOCALLY by TTTL but i did see one by maska; it was white with the same 15" alloys but had vnt decals as well as the same bonnet with the hood scoop and intercooler

I spoke to a few people for advice on whether or not i should install one on my 2.5.... they all said the same thing which was don't do it as i wouldn't have gotten any performance gains, actually might have had a reverse effect (less performance) as fozzy said, the 2kd is designed to not have an intercooler and the 1kd is.. I was told if i wanted to run an intercooler i would have to change the turbo as well..other than that it makes no sense to get one...

I have a 2.5 and i am currently looking into instaling a front mount on the van... you wil not see an increase in performance by just installing the intercooler alone. By installing the ic you can now safely run higher boost pressures than the stock waste gate setting.

The length of piping to do a front Mount versus what Toyota did by having a short distance between turbo and intake makes the big difference in response.

Without evidence, most of the talk is heresay.

Only one way to know and that is to establish benchmarks or baselines with the stock setup, make the modification and then perform the same tests to establish how effective it is.

That's the logic I used on my former subaru project when everybody was talking up their muffler bearing about pressure losses across the core, drop in performance and increased lag etc etc.

I don't know the popular diesel metrics, so look up that first. I assume IAT would be the primary one, and you'll have to dyno before and after to see how a reduction in IAT (if any) would have in performance as well as the cost/benefit.

Install has been performed by another tuner and he documented his observations. ..I am just repeating his findings from what I can recall of that thread