DEFENDER2.NET - View topic - TD5 Performance Intercooler causes Christmas day disaster

↓ Advertise on Defender2 ↓

Home · FAQ · New Posts · My Posts · PMs · Search · Members · Map · Calendar · Profile · Donate · Register · Log In

Home > Td5 > TD5 Performance Intercooler causes Christmas day disaster

Page 1 of 2

Print this entire topic ·

LANDROVER

Member Since: 13 Feb 2016
Location: EAST OF ENGLAND
Posts: 216

TD5 Performance Intercooler causes Christmas day disaster

A job on my list of jobs...
I have a large intercooler, it's been on the 110 for years but I've never been happy with it's fitment.
I replaced the coolant top hose and the replacement was not a one piece one, and it swiftly touched the aux belt. So I replaced and the replacement also has managed to do the same.

I think its because the massive replacement intercooler sits a bit more towards the engine and pushed the radiator also further back.

Does anyone know of any brackets/mounts that address this issue to save me fabricating something.

Thank you.

Last edited by LANDROVER on 26th Dec 2024 5:10pm. Edited 1 time in total

13th Aug 2024 9:55pm

bankz5152

Member Since: 02 Feb 2017
Location: South London/North Kent
Posts: 2185

What intercooler is it?

I would suspect it's not fitted correctly, the mounts into the wings have a fair bit of play in them for adjustment. Instagram @defender_ventures
Empire Tuning - Agent

14th Aug 2024 5:57am

LANDROVER

Member Since: 13 Feb 2016
Location: EAST OF ENGLAND
Posts: 216

Click image to enlarge
My intercooler position

Click image to enlarge

My brother's position

I'm not sure on intercooler. It's been on it since I bought the 110. It's bigger than an original one but I see no maker's name.
When I compare it to another it has forced the radiator back toward engine.
The coolant pipe for thermostat has touched the aux belt.
Christmas day was a disaster as it split and coolant went onto belt causing it to slip. Luckily I noticed something was wrong. I hope it didn't do any damage 😔

I'm not sure if I should try and move the intercooler brackets.
Cut and weld them forward.

Buy a new intercooler and coolant pipes..

I need to sort it asap so got to work out the best route.
Just seems strange if the intercooler is wrong but I guess anything could happen been fitted.

26th Dec 2024 5:09pm

LANDROVER

Member Since: 13 Feb 2016
Location: EAST OF ENGLAND
Posts: 216

bankz5152 wrote:
What intercooler is it?

I would suspect it's not fitted correctly, the mounts into the wings have a fair bit of play in them for adjustment.

I just uploaded pictures.
I'm not sure what the intercooler is.

26th Dec 2024 5:14pm

bankz5152

Member Since: 02 Feb 2017
Location: South London/North Kent
Posts: 2185

Is it the original engine?

Looks like a D2 top house

You need to take the cowling off so we can see how its mounted.

Its 4 screws Instagram @defender_ventures
Empire Tuning - Agent

26th Dec 2024 6:32pm

LANDROVER

Member Since: 13 Feb 2016
Location: EAST OF ENGLAND
Posts: 216

Thank you for replying.

As far as I know original engine .. though something I don't know.
I've had it a few years now but no history.

Top hose is a replacement one.
The original was a one piece type but I replaced but when I removed it have been cut and joined if I remember right.

Are the original intercoolers the same as tdci ones?
My friend changed his to upgraded ones so he might have a spare.

26th Dec 2024 10:11pm

rustandoil

Member Since: 08 Sep 2012
Location: Cotswolds
Posts: 749

2005 Defender 110 Td5 XS DCPU Bonatti Grey

As suggested, I think we need a couple more pictures with the cowl off.... The fan must be very close to the rad?

27th Dec 2024 7:24am

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8077

2011 Defender 110 Puma 2.4 USW Stornoway Grey

I would suggest the diagnol supports ares still fitted meaning it's mounted further back.

Or its an incredibly thick intercooler.

If leaving it as it currently is that top hose needs shortening to eliminate the constriction on the 90 bend. Presumably a longer hose from stat is needed as its pulled further back and is taking direct, shorted path to reach stat housing and that interacts with the fan. Cheers

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

27th Dec 2024 8:53am

LANDROVER

Member Since: 13 Feb 2016
Location: EAST OF ENGLAND
Posts: 216

I will look later as I had to leave it elsewhere.
I cut the top hose to make it clear the aux pulley but the hose leaked on on of the bands that crimp it on.

So I need to find a new hose.

I'm hoping to ring round and find some parts today to get it back together and running.

27th Dec 2024 9:25am

LANDROVER

Member Since: 13 Feb 2016
Location: EAST OF ENGLAND
Posts: 216

rustandoil wrote:
As suggested, I think we need a couple more pictures with the cowl off.... The fan must be very close to the rad?

Yes it runs very close.
I have cut fan shroud as it used to.rub on acoustic cover.

27th Dec 2024 9:27am

LANDROVER

Member Since: 13 Feb 2016
Location: EAST OF ENGLAND
Posts: 216

jst wrote:
I would suggest the diagnol supports ares still fitted meaning it's mounted further back.

Or its an incredibly thick intercooler.

If leaving it as it currently is that top hose needs shortening to eliminate the constriction on the 90 bend. Presumably a longer hose from stat is needed as its pulled further back and is taking direct, shorted path to reach stat housing and that interacts with the fan.

27th Dec 2024 9:31am

htb2

Member Since: 02 Nov 2018
Location: Carmarthenshire
Posts: 532

Puma and TD5 intercoolers are the same.

27th Dec 2024 11:56am

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8077

jst wrote:
I would suggest the diagnol supports ares still fitted meaning it's mounted further back.

Or its an incredibly thick intercooler.

If leaving it as it currently is that top hose needs shortening to eliminate the constriction on the 90 bend. Presumably a longer hose from stat is needed as its pulled further back and is taking direct, shorted path to reach stat housing and that interacts with the fan.

Diagonal support's?
I will check. From what I could see without stripping it out to.look was the brackets which attach to the wings have the locating point for intercooler.
That position makes it sit back and radiator is fastened tonite making it also back.

The brackets on the wings have elongated holes but this is like 2" back from where it should be.

If a puma intercooler is the same I might be able to grab one from a friend to fit instead as he swapped his out for aftermarket ones.[/quote]

The brackets must be fitted further back than std either for a very thick, ie double normal upgraded intercooler thickness or to allow fitment with the diagnol supports still fitted.

Cut or not the top hoses is too long hence the resection on the bend. Cheers

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

27th Dec 2024 3:27pm

bankz5152

Member Since: 02 Feb 2017
Location: South London/North Kent
Posts: 2185

I reckon the rad pack has come out of its mounts and touching the fan because of loose fittings on the slam panel. Instagram @defender_ventures
Empire Tuning - Agent

27th Dec 2024 3:35pm

LANDROVER

Member Since: 13 Feb 2016
Location: EAST OF ENGLAND
Posts: 216

Click image to enlarge

29th Dec 2024 12:03pm

Page 1 of 2

All times are GMT

Jump to

< Previous Topic | Next Topic >

Posting Rules

You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum