One of the biggest differences between the D22 Navara ZD30DI and the GU Patrol ZD30DI is that the Navara is not intercooled from factory.
Because of this, intake air temperatures (IATs) can become quite high — particularly when towing, climbing long hills, or driving in hot conditions.
Installing an intercooler is one of the most noticeable and worthwhile upgrades on the D22 platform.
Why Intercooling Matters
Without an intercooler, compressed air from the turbo goes straight into the engine. As air is compressed, it heats up. Hot air is less dense, which reduces oxygen content and therefore limits power.
High intake air temperatures can result in:
- Reduced power under sustained load
- Higher exhaust gas temperatures (EGTs)
- Reduced efficiency
- Power dropping off when towing or climbing
Even on a stock turbo and stock tune, fitting a basic intercooler will typically result in:
- Power and torque holding on for longer
- More consistent performance
- Improved towing behaviour
You may not notice a huge peak power increase, but you will notice improved consistency under load.
Using a Patrol Top-Mount Intercooler
A common upgrade path is fitting a GU Patrol ZD30DI top-mount intercooler to the D22.
To do this, typically required:
- Patrol ZD30DI valve cover (to suit top-mount design)
- Modified piping between turbo and intake manifold
- Bonnet scoop for airflow
- A fan is recommended, which will need a body lift
A body lift can make the installation process easier by providing additional clearance.
While this is a proven solution, it does require fabrication and supporting modifications.
Front-Mount Intercooler (Preferred Option)
Front-mount intercoolers (FMIC) are generally the preferred option for the D22.
Advantages include:
- Direct airflow from the front of the vehicle
- Reduced heat soak compared to top-mount setups
- Larger core potential
- More consistent intake air temperatures
There are several pre-fabricated front-mount kits available on the market.
HPD offers a well-known and proven front-mount kit for the D22 platform.
Front-mount systems typically offer the best overall thermal performance, especially for vehicles used for towing or sustained heavy load.
Custom and DIY Options
There are also custom intercooler options available, including:
- Custom top-mount setups
- DIY front-mount systems
These require careful planning to ensure:
- Proper airflow
- Good pipe routing
- Minimal restriction
- Adequate cooling support
As with any intercooler setup, core quality and internal fin design are important — not just physical size.
Summary
- The D22 ZD30DI is not intercooled from factory
- High intake air temperatures limit sustained performance
- Even a basic intercooler significantly improves consistency under load
- Patrol top-mount setups can be adapted with supporting modifications
- Front-mount systems are generally preferred
- HPD offers a proven front-mount kit
- Custom and DIY solutions are also possible
For the D22 Navara, adding an intercooler is one of the most beneficial performance and reliability upgrades — particularly for towing and long-distance driving.