Toyota Yaris GR Intercooler

do88 performance intercooler designed for easy installation in your Toyota Yaris GR!

Key features

• Larger core volume: 13,971 cm³ vs 7,320 cm³, 91% larger!
• Larger active cooling area: 2451 cm² vs 913 cm², 168% larger!
• Larger connections: 63 mm vs 45 mm, 95% larger area!
• Airflow at 0.175 bar pressure drop: 300 CFM (226 CFM), 33% higher!
• Peak power increase together with do88 turbo inlet by 26 hp (at the wheels)! Measured on a car with TTE400 turbo, Syvecs control system, etc.
• Lower temperature after intercooler under the same test conditions: 25°C (50°C), 25°C lower!

Background

This do88 charge air cooler is designed for the best cooling capacity under demanding driving conditions. During the development of this intercooler, we were determined to increase the cooling area (frontal area) of the core. A larger cooling area significantly improves cooling across the entire speed range with a correctly designed core and end tanks. A low/thick intercooler, which is significantly easier to design for this car, will usually only cool better at high speeds (high air velocity is required to push the cooling air through a thick core). We saw our approach as obvious, as we anticipate this car will also be used on technical tracks with lower average speeds.

To increase the cooling area, the crash beam needs to be moved forward so that the intercooler can fit behind it. Therefore, two special spacers were designed to move the crash beam forward; these spacers also became an optimal position to use as mounting points for our intercooler.

What many unfortunately overlook when developing a new intercooler is the need for air guides. Air passages around the intercooler should not be left open, as a large part of the cooling air will escape there instead of passing through the core. We include two “tailor-made” air guides that seal off these bypass areas for the air.

To improve flow (reduce pressure drop) through the intercooler, we increased the size of the connections on our intercooler to 63mm (2.5”) as the original has very restrictive 45mm (1.75”) connections. To ensure our intercooler fits with the original charge pipes, we include two specially designed silicone hoses.

The increased core volume improves cooling capacity and lowers the engine's intake temperature. As this is a do88 performance product, we have naturally carried out thorough tests during the development phase to achieve the best performance. No compromises have been made. This cooler is space-optimized as much as possible to accommodate an intercooler with a large cooling area.

A full 91% larger core volume and 168% larger cooling area is a difference we are proud to have achieved (57mm thick Tube&Fin core). It's something that truly makes a difference. The engine pulls significantly better across the entire rev range and withstands repeated accelerations without building up heat. The notion that the charge air cooler doesn't need to be replaced until a high tuning level is achieved is incorrect, yet widely spread. On warm summer days, during repeated pulls, spirited driving, or generally in a warmer climate, it doesn't take much effort for the engine to start generating dangerously high intake temperatures, even on a completely untuned car. The standard intercooler's cooling capacity is often clearly inadequate, and this negatively affects the engine and its power. Heat must be dissipated, otherwise, the promised power will drastically decrease as soon as you start accelerating.

Some of the original plastic air guides will need to be trimmed (see installation instructions) to allow for the installation of our significantly larger intercooler. The styrofoam attached to the crash beam must be removed during installation. The styrofoam will not fit when the crash beam is moved forward.

This product comes with everything needed for easy installation. Screws, washers, hoses, brackets, clamps, air guides, and installation instructions are, of course, included.

Take care of your engine, choose do88!