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The fourth-generation Toyota Tacoma introduced a new turbocharged 2.4-liter engine, replacing the long-standing naturally aspirated engines used in earlier generations. Turbocharged setups offer increased torque and efficiency, but higher intake air temperatures can reduce performance consistency during sustained load conditions such as towing, off-roading, or repeated high-RPM operation. The Performance Intercooler Kit for the 2024+ Tacoma is designed to address these challenges through improved cooling efficiency, optimized airflow, and precise fitment within the tightly packaged engine bay.
Our engineers began the development process by evaluating the stock intercooler, which already demonstrated during single-run dyno testing. However, extended high-load operation revealed rising charge air temperatures and increased pressure drop, creating additional stress on the turbocharger. The stock core exhibited a peak pressure drop of approximately 2.9 psi. To improve upon Toyota's design, our goal was to design a direct-fit intercooler that reduces pressure drop, lowers charge air temperatures, and maintains consistent performance under repeated stress scenarios while fitting precisely in the available space.
Our upgraded intercooler features a bar-and-plate core that is 55 percent larger than the factory unit and achieves a 10 percent increase in frontal area. This expansion allows more thermal mass and surface area, helping maintain lower charge air temperatures over multiple pulls and extended driving sessions. To maximize airflow through all rows of the core, a new lower duct was engineered to complement the existing factory duct. This duct ensures that air is directed evenly across the entire core despite the tight packaging of the engine bay.
Fitment was a primary consideration during development. Every cutout and dimple in the intercooler’s end tanks is positioned to allow a flush fit against the radiator while avoiding interference with surrounding components, including adaptive cruise control. Engineers verified fitment through multiple prototype iterations, temporarily removing grill shutters during testing to optimize airflow and clearance. Installation requires removal of the radiator to prevent bending or scratching of the fins. The kit includes all necessary hardware, including a new crush washer for the factory temperature sensor and O-ringed fittings for vacuum ports, ensuring a secure and leak-free setup.
Flow efficiency was improved through CNC-machined billet aluminum inlets and outlets, which create precise O-ring seals and minimize restriction. Testing confirmed a reduction in pressure drop from 2.9 psi in the stock unit to approximately 1.9 psi with the upgraded intercooler. Reduced restriction allows the turbocharger to operate with less stress, resulting in improved low-RPM responsiveness and more consistent torque delivery. When paired with the upgraded charge pipes, the system produces modest gains of 2 horsepower and 3 pound-feet of torque, while the main benefit is consistent performance under extended high-load operation.
The kit’s charge pipes are designed to integrate seamlessly with both the stock intercooler and the upgraded core. They provide smooth airflow from the turbocharger through the intercooler and into the throttle body, minimizing turbulence and pressure drop. CNC-machined billet aluminum ports on the intercooler interface with the pipes for a precise O-ring seal, ensuring consistent airflow and reducing the risk of leaks. The pipes are available in wrinkle red or wrinkle black finishes to match vehicle aesthetics and provide a durable, corrosion-resistant surface. They align with factory mounting points and maintain proper clearance in the tight engine bay. During testing, pairing the upgraded pipes with the larger core contributed to reduced pressure drop and improved low-RPM throttle response, ensuring consistent boost delivery across the powerband. The pipes and intercooler function as a system rather than as individual components, maximizing overall cooling and airflow improvements.
Thermal performance was validated through extensive testing. During a single wide-open-throttle pull, charge air temperatures were maintained just 5 degrees above ambient. In a heat soak test consisting of six consecutive pulls without cooldown, charge air temperatures rose only 24 degrees above ambient, compared to higher peaks with the stock intercooler. A torture test simulating a 50 mph third-gear pull at wide-open throttle for 20 seconds, representing uphill towing or sustained load, showed the upgraded intercooler maintained a peak outlet temperature of 99.2°F compared to 135.2°F for the stock unit, representing a 36°F reduction in charge air temperature. These results demonstrate the system’s ability to maintain stable thermal performance under demanding conditions.
The core design ensures even airflow from top to bottom, maintaining consistent cooling across the surface. Cast end tanks provide structural strength while optimizing flow, and billet aluminum inlet ports provide secure and reliable connections for the temperature sensor. A pre-installed 1/8-inch NPT bung allows for optional sensors or methanol injection. Updated mounting bushings accommodate the condition of factory mounts, ensuring proper installation, and the powder-coated core resists corrosion over time.
Lower charge air temperatures and reduced pressure drop decrease stress on the turbocharger, improving throttle response and maintaining power during sustained operation. Heat soak testing showed that the stock intercooler lost up to 5.58 horsepower over six consecutive runs, whereas the Mishimoto intercooler lost only 3.35 horsepower. Single dyno runs also indicated improved low-end torque due to reduced restriction and consistent top-end power through better charge air cooling.
Installation is straightforward for experienced users, but radiator removal is necessary to prevent damage to the radiator fins. All necessary hardware is included, such as O-ring fittings, mounting bushings, and the crush washer for the temperature sensor, ensuring a secure and leak-free setup. Opening the cooling system also provides an opportunity to service the radiator and top off coolant.
By combining a larger bar-and-plate core, CNC-machined inlets and outlets, cast end tanks, and upgraded charge pipes, our Performance Intercooler Kit for the fourth-generation Toyota Tacoma delivers improved thermal management, reduced pressure drop, and consistent performance during demanding driving conditions. Testing confirms up to 36°F lower charge air temperatures in stress scenarios, 30 percent lower pressure drop, and maintained efficiency across the RPM range. The system fits precisely within the stock engine bay, integrates with both OEM and upgraded components, and provides durable, secure connections for sensors and mounts.
This kit allows fourth-generation Tacoma owners to maintain consistent performance under high-load conditions such as towing, off-road driving, and sustained high-RPM operation. By prioritizing consistent cooling, reduced restriction, and precise engineering, it improves upon an already efficient factory system, focusing on reliability and repeatable performance over peak dyno numbers. The design reflects careful attention to airflow optimization, thermal efficiency, and long-term durability, providing confidence that the truck will perform consistently under demanding real-world conditions, ensuring their trucks stay on the road for the long run.