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lakes

Member Since: 08 Jan 2023
Location: Lake District
Posts: 22

2010 Defender 90 Puma 2.4 XS CSW Santorini Black

Intercooler upgrade

I posted this time last year asking for advice on why my 2.4 was going into limp mode when going 70+, on a hot day and with the AC on.

Turns out it’s the Intercooler - it’s not big enough to deal with all the heat in the conditions listed above.

Maybe a stupid question but I’m going to go for an Alive ultimate Intercooler and get the silicone hoses. Does getting a bigger Intercooler make the engine take longer to heat up in winter or any other ‘negative’ effects?

22nd Jun 2024 5:30pm

BaronDefenders

Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 896

2004 Defender 90 Td5 CSW Santorini Black

No negative effects, whatsoever! Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders

22nd Jun 2024 5:41pm

MK

Member Since: 28 Aug 2008
Location: Santiago
Posts: 2415

2007 Defender 110 Puma 2.4 SW Chawton White

I do not think it is an intercooler problem, but rather the cooling system. It is known issue. Puma 110" SW

.............................................................
Earth first. Other planets later

22nd Jun 2024 8:44pm

Welshsurferdude

Member Since: 23 Feb 2012
Location: Newport
Posts: 2406

Upgrade the radiator too

provided that everything else is working as it should 2008 Santorini Black 110 XS USW (Sold)

2015 Discovery 4.5 Black pack Firenze red XS

2008 Corris Grey 110 XS USW (sold)

2011 Santorini Black 110 XS USW (Sold)

Last edited by Welshsurferdude on 23rd Jun 2024 9:00am. Edited 1 time in total

22nd Jun 2024 9:09pm

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8026

2011 Defender 110 Puma 2.4 USW Stornoway Grey

2.4 doing 70mph on a hot day with ac on, limp mod shouldn't be anywhere on the agenda assuming everything is working as it should be.

As above I would start with cooling system. Pipework, water pump, correct level, correct flow, good rad.

Ambient temperature doesn't make much odds to intake temp in the scheme of things. Cheers

James
110 2012 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

23rd Jun 2024 8:58am

Chicken Drumstick

Member Since: 17 Aug 2020
Location: Near MK
Posts: 724

Re: Intercooler upgrade

lakes wrote:
I posted this time last year asking for advice on why my 2.4 was going into limp mode when going 70+, on a hot day and with the AC on.

Turns out it’s the Intercooler - it’s not big enough to deal with all the heat in the conditions listed above.

Maybe a stupid question but I’m going to go for an Alive ultimate Intercooler and get the silicone hoses. Does getting a bigger Intercooler make the engine take longer to heat up in winter or any other ‘negative’ effects?

How do you conclude that the standard intercooler is too small for doing a standard thing such as running at motorway speeds? Do you not think the factory and the thousands of people who bought these might have done this sort of thing?

Upgraded intercooler will be an improvement in performance even without a remap. But I doubt it’ll fix the fault you are experiencing. I would focus on repair rather than modifying at this stage.

23rd Jun 2024 1:23pm

andy63

Member Since: 30 Jun 2023
Location: north east
Posts: 514

jst wrote:
2.4 doing 70mph on a hot day with ac on, limp mod shouldn't be anywhere on the agenda assuming everything is working as it should be.

As above I would start with cooling system. Pipework, water pump, correct level, correct flow, good rad.

Ambient temperature doesn't make much odds to intake temp in the scheme of things.

I may be missunderstanding but the ambient temp will determine the intake temp.. With the best intercooler in the world and travelling at a good speed the intercooler can't do better than ambient temp for the engine intake temp👍..
I have seen my ambient and intake temp the same but there is usually about a degree or so between them.. But that's popping along and it's a bas upgraded intercooler..

23rd Jun 2024 3:08pm

lakes

Member Since: 08 Jan 2023
Location: Lake District
Posts: 22

I was advised it was the Intercooler by my independent last year when the problem started - they also mapped it but it’s smoked ever since and I’m not really happy with it.

It’s only done it 3 times, always on a really hot day.

Anyways, I’m making the pilgrimage to Alive to have them give it a once over, smoke test and hopefully Intercooler, hoses and new map done.

25th Jun 2024 6:40pm

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8026

thats your problem then. mapped for too much fuel hence the smoke and making it run hot. Cheers

James
110 2012 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

25th Jun 2024 6:54pm

Notyalc

Member Since: 27 Jul 2018
Location: Northumberland
Posts: 161

lakes wrote:
I was advised it was the Intercooler by my independent last year when the problem started - they also mapped it but it’s smoked ever since and I’m not really happy with it.

It’s only done it 3 times, always on a really hot day.

Anyways, I’m making the pilgrimage to Alive to have them give it a once over, smoke test and hopefully Intercooler, hoses and new map done.

Maybe best to get an Alive map while you are there…

25th Jun 2024 6:57pm

Zed

Member Since: 07 Oct 2017
Location: In the woods
Posts: 3287

2010 Defender 110 Puma 2.4 XS CSW Santorini Black

jst wrote:
thats your problem then. mapped for too much fuel hence the smoke and making it run hot.

My first thought too, also I’m very surprised the indie remapped it knowing there was an issue with the intercooler.
I’m sure Alive will get to the bottom of it though. Let us know how you get on. WARNING.
This post may contain sarcasm.

25th Jun 2024 7:02pm

Notyalc

Member Since: 27 Jul 2018
Location: Northumberland
Posts: 161

There may not be a problem with the intercooler…

25th Jun 2024 8:34pm

MK

Member Since: 28 Aug 2008
Location: Santiago
Posts: 2415

agree.

The overheating issue also depends how you drive regarding the gas pedal position vs RPMs (as a function of gear selection and speed). Puma 110" SW

.............................................................
Earth first. Other planets later

25th Jun 2024 11:30pm

Chicken Drumstick

Member Since: 17 Aug 2020
Location: Near MK
Posts: 724

lakes wrote:
I was advised it was the Intercooler by my independent last year when the problem started - they also mapped it but it’s smoked ever since and I’m not really happy with it.

It’s only done it 3 times, always on a really hot day.

Anyways, I’m making the pilgrimage to Alive to have them give it a once over, smoke test and hopefully Intercooler, hoses and new map done.

Ok some critical info left out of your opening post. Remapping on a stock intercooler is not really advised IMO. It is the wrong mod to do first. Certainly if it is now smoking and causing over heating, your EGT’s must be through the roof.

Based on this and fact they applied such a map to a stock vehicle I’d also want to question the quality of the map. There are lots of very poor maps around that seem to get shared online and reused by people with too little knowledge to know what they are doing.

Options you have are:

-return to a standard map. This will likely fix the problem.
-add a big intercooler. This “may” fix the problem. But might not. Also do note that not all aftermarket intercoolers are equal. Which means the map may be intended for a specific grade of intercooler.
-fix a big intercooler and get a custom remap. For me this would seem the best solution and given that the cost of a custom map is not all that much. You should end up with a vehicle that runs way better and hassle free and without the smoke.

26th Jun 2024 8:13am

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8026

I suggest you find anther garage to do the work for you other than your current independent.

Unless of course they mapped it and said you need a larger intercooler to go with this map, it won't worked well otherwise, and you declined?

Betting is your intercooler is fine and work wonderfully with a standard map.

Best to get a map that's been developed and tested for the application you require for the hardware you have. Cheers

James
110 2012 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

26th Jun 2024 9:32am

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