Next-Gen Ranger — Fenix brings the cooling

March 24, 2025

There aren’t many upgrades on the market as effective as this, especially for the ease and the cost. We spent the afternoon with Fenix Radiators to check out their Kiwi-designed Next-Gen Ford Ranger intercooler kit, for both the four- and six-cylinder diesels. Want a drop in intake air temps of more than 20 degrees in less than 45 minutes? Read on...

There’s no denying just how good the Volkswagen-engine Next-Gen Ford Ranger is, but there are a few downsides to the new platform from Ford. One of the major downsides is the lack of tuning options out there at the moment for both platforms. The other issue is that the four-cylinder variant is right on the edge — it’s a fairly ‘pushed’ engine from the factory. The V6 variant is the better of the two for future modifications, but both suffer from high-intake air temps due to a small intercooler, and the factory silicone hose design is prone to failure, as seen on previous models.

With plenty of experience designing Ford Ranger kits for earlier models, Fenix — working hand-in-hand with CTB Performance — saw the need to produce a similar intercooler kit from the outset to mitigate failure in your four-wheel drive, touring, or camping Ranger. There’s nothing quite like having an intercooler hose split or come off in the middle of nowhere (yep, it’s happened to us). And with the four-cylinder variant pushed fairly hard from the factory, lower intake air temps mean a longer lifecycle. Towing with your four-cylinder, or have a big ol’ heavy tool chest on the back? This is designed with you in mind. A cooler intake charge means denser air and lower EGTs as a flow-on effect.

The V6 variant is a more performance-focused platform, with tuning options expected on the market early next year. The first limitation, though, is the small factory intercooler and factory piping. Whether you tune it or not, the newly designed intercooler kit by Fenix can be installed at home in under 45 minutes — you don’t even need to remove the bumper! One of their key design points was having the DIY enthusiast in mind — hardly any of us have a hoist at home, so it had to be an easy install with basic tools. So, if you’re looking to lower intake air temps and improve the reliability of your new Next-Gen Ranger, here’s the info you need!

If you study the intake air temperature diagram, as tested by CTB Performance, you’ll notice a few things about the factory intercooler (red) and the Fenix Radiators intercooler upgrade (blue). Under load conditions, the factory intercooler is overcome with heat soak. You can see it manages the heat to a point, then the intake air temperature continues to climb sharply. This might be the difference between passing with a loaded rig or sitting in the slow lane — one big pull under load and engine performance will decline rapidly. With the Fenix intercooler fitted, you can see that it not only drops the initial intake air temperature, but under the same test conditions, it only peaks just higher than where the factory temperature begins. It isn’t easily overcome by heat either, as you can see a slight increase in temperature, but it’s a slow, gradual climb. In the real world, you’re likely to feel this at the top of a long passing lane. The factory cooler will be heat-soaked, but the Fenix won’t be — you’ll still be pulling at the end of the passing lane.

Ford Ranger four-cylinder and V6 diesel intercooler upgrade:

Designed and tested in New Zealand in conjunction with CTB Performance.
Intercooler capacity increased by 37.5 per cent.
Intercooler: Bar and plate construction with staggered internal fins for maximum efficiency.
Intercooler: Fully TIG-welded construction vs factory use of plastic-crimped end tanks.
Piping: All aluminum, mandrel bent. Includes silicone joiners and hose clamps. Factory utilises long rubber hoses prone to premature deterioration (as seen with the PX Rangers) and quick-connect fixtures that are prone to failure under additional boost.
CNC fittings for factory-fit OEM air temp sensor, turbo outlet (V6 model).
Lower intake air temps (over 20 degrees).
Available in black or silver (and polished piping) finishes.

Now, let’s install one to show you how easy it really is!

How to install the Fenix intercooler upgrade on your Next-Gen Ford Ranger

If you’re ready to lower intake air temps and improve reliability on your Next-Gen Ranger, here’s a simple step-by-step guide to install the Fenix intercooler. You don’t need a hoist or even remove the bumper, making it the perfect DIY job. Let’s get started!

What you’ll need:

Basic tools (socket set, screwdrivers, etc.)
Fenix Intercooler Kit (includes all necessary hoses, clamps, and fittings)
Your vehicle’s user manual (for reference)

Estimated time: 45 minutes

Step 1: Disconnect and remove
Start by disconnecting the battery. Once that’s done, remove the factory airbox, bash plate, intercooler, and stock piping. Follow your vehicle’s user manual or consult a professional if needed.

Step 2: Transfer and install the intercooler

Take the rubber mounting bushes from the factory intercooler and transfer them to your new Fenix Pro Series Intercooler. With the bushes in place, fit the new intercooler into the factory location. It’s a straightforward swap that uses the stock mounting points.

Step 3: Install the cold-side piping
Now, grab the intake alloy intercooler pipe and secure it using the provided silicone joiner and hose clamps. Attach the upper side of the pipe to the throttle body first, then fit the lower half to the intercooler. Ensure everything is snug and properly aligned.

Step 4: Reconnect the air temp sensor
Once the intake pipe is fitted, reconnect the OEM air temp sensor to the top side of the pipe. Double-check that it’s seated correctly.

Step 5: Install the hot-side piping
Next, move to the driver’s side and install the upper hot alloy intercooler pipe. Use the silicone joiner and clamps to attach the upper pipe to the turbo outlet. Then, fit the lower hot-side pipe to the intercooler. Make sure the pipes are well-secured using the provided hose clamps.

Step 6: Reassemble and test
Reinstall the airbox and battery. Before hitting the road, start the vehicle and check for any leaks in the intercooler system. If everything looks good, go ahead and reinstall the factory bash plate.

That’s it! Your Ranger is now running cooler with a more robust intercooler setup, all in under an hour.

Let’s hit the road!

There’s not much better than feeling your mods, but hearing them is up there. There’s nothing better than the sound of a turbocharger spooling, and this was the very first thing we noticed after jumping in the Ranger once Ben from Fenix installed the kit. There’s a definite increase in intake noise and initial torque, with the inlet air temperatures running cooler. The best thing is, we could feel a difference without a tune. However, this intercooler will come into its own under load and once it’s tuned. Towing will be easier, hauling your camping equipment around New Zealand will be a breeze, and getting to the top of those passing lanes? Well, you’ll be leading the pack. In under an hour, the Fenix team had given this Ranger increased capacity for thermal loading of the intercooler, prepared it for tuning, and improved turbocharger response and torque. It’s safe to say, if we had a Next-Gen Ranger, we’d be all over this upgrade!

You can purchase this intercooler kit, here: Ford Ranger P703 / RA 3.0L V6 Diesel 2022