The original top-mounted intercooler on the 120 Series D4D is considered restrictive and prone to heat soak.
Solution
Install a front-mounted intercooler (FMIC) kit from Cross Country 4x4.
Parts
- Cross Country 4x4 FMIC kit for 120 Series D4D (including intercooler and pipework)
Cost
- FMIC kit: Approximately $1580
- Installation: Approximately $400
Notes
- Installation requires relocation of the winch control box and air horn, and modification/removal of plastic tabs and brackets.
- Foam sealing is used to direct airflow from the viscous fan to the condenser core.
- A Tunit chip from Opposite Lock SA, with a custom tune to suit the FMIC, was used after the intercooler install.
- A 3-inch exhaust system was mentioned as a potential future upgrade.
- It’s recommended to monitor injector values, and check the oil pump pickup screen, before performing engine modifications.
This technical summary was auto-generated based on recovered archives. Do not rely on its factual accuracy. Refer to the original thread. Source: View Original Conversation
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