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Hufflepuff

Member Since: 25 Oct 2014
Location: Hampshire
Posts: 727

How easy is it to fit an Intercooler to a Td5 with aircon?

Hello all,

I'm struggling to find an answer to this question - just how easy is it to fit an intercooler to a Td5 with the aircon radiator in place?

I understand that its quite simple on vehicles without aircon - just pop off the grill, remove the old one and fit the new one - but with aircon in place (and no ability to de-gas it) do I have to remove the viscous fan, then the main radiator and then the old intercooler?

Trying to upgrade the 90 - but living deep in the south doesn't seem to be putting one of the well respected tuning companies within easy driving reach. An option which has been suggested is getting an intercooler and map-tool by mail order, and doing it myself.

I have some limited spannering ability - but as this is my only motor, if it goes wrong and I need a spare part I'll be in trouble! On the handy Haynes spanner count, (1-5 where 1 is get out of bed in the morning and 5 is rebuilding the Death Star), what would you rate this job at?

Thanks!

4th Nov 2014 11:14pm

bga86

Member Since: 17 Jan 2014
Location: Here and there
Posts: 205

No need to remove fan or radiator, take grill off, in do slam panel nuts from both sides then you need to take the studs out of the wings so it will lift out the way, then undo the radiator/air con rad mounts, move the air con rad forward slightly and you can get the old cooler out and new one in. It's a pretty fiddly job and you need to be careful not to damage pipes, if you aren't very hands on I'd probably advise getting an Indy to do it or have a mechanic friend close by

5th Nov 2014 7:50am

Hufflepuff

Member Since: 25 Oct 2014
Location: Hampshire
Posts: 727

Thanks for the reply bga. If I can get away without removing either of the rads, I feel a bit more confident about tackling the job myself - just take it nice and slow.

Now to decide on which intercooler to get. The Alive one looks nice.

5th Nov 2014 1:22pm

Chocolate

Member Since: 18 May 2012
Location: Berkshire
Posts: 153

2004 Defender 110 Td5 XS CSW Bonatti Grey

Hi Hufflepuff,

I did mine last year, Allisport intercooler. Getting the slam panel off is fiddly but not too bad. I changed the hoses as well. Getting the old intercooler out is hard especially as the hose clamps are installed before the wings are put on. So I had a very hard time trying to reach one. It took me a while to undo this. There isn’t a great deal of room to do up the new ones either. It’s a very satisfying job to do. I wasn’t happy with one of the hose clips so I ended up unbolting everything again.
Allisport have instructions on line on how to do it all.
I had to cut one of the plastic brackets for the intercooler to fit, don’t know if you still need to do that.
Took me around 4-5 hours in total, but then I wasn’t going fast and ended up spraying waxoil to parts that were hard to get to while things we off.

110XS CSW TD5.

5th Nov 2014 2:03pm

Hufflepuff

Member Since: 25 Oct 2014
Location: Hampshire
Posts: 727

This has to be one of the most friendly and helpful car forums I've ever come across! Thanks for your advice Chocolate, I'm getting more and more confident about doing the job by the hour

5th Nov 2014 2:16pm

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