3.0lt GU Patrols - Grenade Facts

[apalsson]

For me the jury is out on a larger intercooler, do you get $800 worth of extra cooling[lower EGTs] over a tigged OE one, you decide
I think its $800 I could spend elsewhere, but that's just me

I agree with 3Dogs on this one. My old Patrol was a 2001 model, bought new and modified for outback work. That car was heavily used for some hard work including towing, first an Ultimate Offroad Camper and later a Supreme Getaway offroad caravan.
I did around $140,000 - 150,000Km in 2 1/2 years, including some 55,000km outback. This car never let me down which I mainly attribute to:
1. Maintenance: I faithfully had the car serviced as per Nissan's maintenance schedule every 10,000Km and if I did any hard outback trips, replaced all oils after 5,000Km
2. Cooling: My Patrol had a Nissan bulbar and a low-mount winch. I always made sure there were no restrictions to airflow in through the front grille. May of the cars that have blown engines have had high-mount winches fitted that partly restrict airflow through the radiator
3. Snorkel: These cars greatly benefit from a well fitted snorkel as it improves the flow of cool fresh air into the engine

Again, I agree with others on fitting the gauges (boost and EGT) to see what is going on inside the engine but have to say I think replacing the Intercooler "just in case" is a heavy handed approach. If there is genuinely nothing wrong with the IC, why replace it.
The $800 - $1,400 a replacement IC can cost you are in my opinion much better spent on other things.