Process West Top Mount Intercooler w/Shroud Kit Black Subaru Forester XT 2004-2007

Product Fitment: 

2004-2007 Subaru Forester XT

Note: Designed for use with the 2002 STI high-flow hood scoop.

The Process West Top Mount Intercooler Kit is engineered to improve cooling efficiency, reduce heat soak, and maintain more consistent power for the Subaru Forester XT.

Rather than simply increasing intercooler size, Process West designed the core, splitter, and Y-pipe as a complete system to maximize airflow and charge-air distribution.

Key Features & Benefits

• 90mm high-efficiency intercooler core
• Vehicle-specific splitter directs airflow across 100% of the core
• High-flow moulded silicone Y-pipe
• Improved charge-air distribution across the full intercooler
• Helps reduce intake temperatures and heat soak
• Supports more consistent throttle response and power under load
• Complete system with matched ducting and airflow components

Optimized 90mm Core

Process West uses a 90mm core rather than the thicker 114mm designs found on some aftermarket intercoolers. Since airflow entering a top-mount intercooler must make a sharp turn through the hood scoop, excessive core thickness can create unnecessary restriction.

The 90mm design balances cooling capacity with airflow efficiency, allowing ambient air to move effectively through the core.

Full-Core Airflow

A larger intercooler is only effective when the ducting can direct air across the entire core. Factory splitters may leave a significant portion of an upgraded intercooler without direct airflow.

The Process West splitter is sized specifically for the larger core, helping deliver ambient airflow across 100% of the intercooler surface.

High-Flow Silicone Y-Pipe

The included Process West silicone Y-pipe is engineered to distribute compressed air evenly across the full width of the intercooler, helping maximize cooling efficiency and core utilization.

Proven Performance

Back-to-back testing on a 2005 Subaru WRX showed:

• Process West system: 115.5 kW
• Factory intercooler: 107.5 kW
• Process West peak outlet temperature: 51°C
• Factory peak outlet temperature: 66°C

After three consecutive dyno runs, the factory intercooler reached 84°C and continued climbing.

During spirited mountain driving:

• Process West system: maximum 43°C
• Factory intercooler: 72°C and still increasing

What's Included

• Process West 90mm top mount intercooler
• Vehicle-specific intercooler splitter
• High-flow silicone Y-pipe
• Required mounting hardware and fittings