 | Home > Maintenance & Modifications > How is the Intercooler on a Td5 removed? |
 
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| jonny2tanx Member Since: 06 Jul 2014 Location: Harpenden, Herts Posts: 156   
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Not sure about car with air con but this weekend when I replaced the crankshaft pulley and radiator I had to unbolt the 2 brackets either side of the radiator, the one that hold the bonnet stay on the drivers side and I think, the clip on the passenger side. You may be able to just undo one of the small bolts and swing it up out of the way, but the bonnet cable on the drivers side one may get in the way. (You have already removed the 2 front bolts on either side to remove the slam panel. You can either remove the bonnet or fasten it back against the screen as the bonnet will have no support.
If it's too much like hard work, I'll be kind enough to take the intercooler of your hands for a reasonable sum  |
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25th May 2015 7:37pm |
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| Hufflepuff Member Since: 25 Oct 2014 Location: Hampshire Posts: 723  
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Ahhh the brackets are removable too? Just been reading Alive's instructions (http://alivetuning.com/docs/Defender%20Td5%20Intercooler.pdf) which seem to imply the same thing. I shall go out in the morning with renewed enthusiasm, thanks Jonny.
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25th May 2015 8:35pm |
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| jonny2tanx Member Since: 06 Jul 2014 Location: Harpenden, Herts Posts: 156
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Good luck. I'm not sure how the air con condenser fits, and whether that is part of the radiator and intercooler pack. The Alive instructions do specify they (the instructions) are for cars without air con. I hope the air con pipes don't get in the way. I reckon you may have problems with the intercooler jubilee clip if it faces the wing as I don't think there will be space to pull the hose through - the intercooler needs to come forward as it is as the stubs fit in cut outs in the side of the radiator either side. You may need to consider moving the rad backwards a bit if possible without draining and undoing the hoses - you'd need to lift it off the bottom mounts about 40mm or so unless it will lean backwards. Maybe that will give you access to the clip and enough room to move the intercooler forward to clear the rad? Otherwise it could be a rad/intercooler out job if that can be done without disturbing the air con pipes?
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25th May 2015 10:04pm |
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| Hufflepuff Member Since: 25 Oct 2014 Location: Hampshire Posts: 723
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Thankfully the air con radiator is a separate unit mounted on an A-frame at the front - with a good inch of clearance to the intercooler. You might be right about the last remaining juby-clip, my longest 6mm spanner is still about an inch short of reach, but perhaps it will pull far enough forwards to reach.
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25th May 2015 10:44pm |
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| jonny2tanx Member Since: 06 Jul 2014 Location: Harpenden, Herts Posts: 156
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Good luck with it
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25th May 2015 11:37pm |
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| jonny2tanx Member Since: 06 Jul 2014 Location: Harpenden, Herts Posts: 156
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So how did you get on?
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26th May 2015 9:16pm |
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| Hufflepuff Member Since: 25 Oct 2014 Location: Hampshire Posts: 723
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Right, success at the cost of the skin on my knuckles and yet another full day out on the drive...
With Jonny's information about removing the mountain plate, I was able to get the old intercooler out. The four studs needed extracting from the front (2 on each plate):  Click image to enlarge ... and then remove the two rear bolts on each plate: Click image to enlarge allowing the old intercooler to be gently removed from frame. We can then compare the old to the new - interestingly the new one is not much thicker (if any), but considerably taller. Click image to enlarge Click image to enlarge As the Haynes manual then says "refitting is the reverse of removal". Well at least as far as putting the new intercooler in place it was: Click image to enlarge Lots of the guides talk about removing some of the plastic trim/fins around the radiator. I did not see what I needed to cut - I couldn't see anything which was obstructing the intercooler from fitting - did the radiators change in the 2002 Td5 refresh? Well then we got to the meat and two veg of the operation. I thought removing the pipe on the (vehicle) left hand side had been difficult - but it was NOTHING compared to trying to fit the new one. The air was blue with swearing.... Air con pipes make getting your hand close to the intercooler impossible. After *MANY* hours, I did manage it, but I shall never do this job again - a job for the professionals next time. Click image to enlarge Click image to enlarge Went for a spin, seems to hold together so a job done. Turbo lag seems a little worse now (I suppose that's to be expected given the bigger volume of air), but it seems to pull a little harder when the boost does kick in. Wanted to do the EGR at the same time but ran out of daylight, so that's for another day. Exhaust next, then remap time  |
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26th May 2015 9:32pm |
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| jonny2tanx Member Since: 06 Jul 2014 Location: Harpenden, Herts Posts: 156
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Congratulations on your achievement. It'll be far easier next time
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26th May 2015 10:22pm |
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| rustandoil Member Since: 08 Sep 2012 Location: Cotswolds Posts: 664 
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I've done this job twice
 best described as fiddley and time consuming, I am very surprised you didn't need to trim the two plastic lugs off the radiator 
You now need a re-map to make the best of your new intercooler  |
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27th May 2015 7:00am |
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| Hufflepuff Member Since: 25 Oct 2014 Location: Hampshire Posts: 723
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I'm concerned about the same thing Eddie. Do you know if it would be really obvious and impossible to fit without trimming them, assuming that they were present?
I wonder if the air-con vehicle radiators didn't have the lugs on? I did look for something to trim (I was expecting it), but couldn't see anything which would be in the way |
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27th May 2015 12:08pm |
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| munch90 Member Since: 26 Oct 2013 Location: guildford Posts: 3558
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I needed to trim the lugs on a tdci , also a a/c pipe was a bit too close just slight bend out of the way
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27th May 2015 12:11pm |
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| rustandoil Member Since: 08 Sep 2012 Location: Cotswolds Posts: 664
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I certainly had to trim the two lugs on the radiator to fit my Allisport intercooler to my 2005 air-con 110, I don't know if the Alive intercooler has a slightly different method of mounting? there isn't much space though........
The Alive PDF instructions show the the lugs need to be cut |
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27th May 2015 1:11pm |
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| K9F Member Since: 12 Nov 2009 Location: Bournemouth Posts: 9610 
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Same brand of intercooler, same issues which is somewhat reassuring. Took me 12 hours start to finish to fit. Most difficult was the fitting of the silicone unions at the ends of the stainless pipes. It will compliment your intended remap perfectly and then you should notice a difference.
Pictures have long gone but they were very similar from my Puma. Can remember it took my hands about a week to heal! http://www.defender2.net/forum/topic13612.html?highlight=claret If you go through life with your head in the sand....all people will see is an ar5e!! Treat every day as if it is your last....one day you will be right!! |
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27th May 2015 2:12pm |
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| Hufflepuff Member Since: 25 Oct 2014 Location: Hampshire Posts: 723
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I wonder why I didn't notice/need to trim the radiator lugs, I'm quite concerned I missed something now! I did look for them but just couldn't see where they were on the radiator. I'm pretty sure that it is the original radiator, as the stupid house clamps would have been near impossible to do up with the wing in the way. hmm...
And K9F yes my hands (well right hand one) are a right mess today. As well as all the raw skin, I somehow ended up with a 3" bruise just above the wrist, no idea how I did that, must have been in one of the many moments of rage during fitting  |
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27th May 2015 10:47pm |
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