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ZeDefender



Member Since: 15 Sep 2011
Location: Munich
Posts: 4731
Germany 2011 Defender 110 Puma 2.4 SW Baltic Blue
Final check before fitting an intercooler
Good morning all!

With the impending delivery of my new intercooler from BAS this week - sooo excited Razz - I just wanted to check I am "install-ready".

I copied this brief info from a thread ages ago (many thanks to the poster) but can't find it now:

Remove fan cowling and grill.
Loosen 2 bolts on bottom of AC radiator housing.
Remove only right side 2 b"bolts" of the bonnet catch plate on the radiator side of fender by using a vice grip. (you will destroy these 2 bolts so make sure you have 2 spare bolts to replace these! I used normal bolts for future ease) OR use 2 nuts to lock then undo.
Loosen 2 I C pipes and bolts.
Pull old I C.
Trim 2 plastic edges of radiator slightly.
Pop new I C in and secure bolts and pipes.

Are there any other tips or tricks I should be aware of? Does anyone know of a "how to" with pictures?

Cheers
Matt Tell someone you love them today because life is short.
But shout it at them in German because life is also terrifying and confusing...
Post #328201 4th May 2014 6:19am
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Regard



Member Since: 08 Dec 2011
Location: RSA
Posts: 251
South Africa 2011 Defender 110 Puma 2.4 X-Tech LE Orkney Grey
Hi Matt

That looks pretty much like info I posted ages ago after installing the intercooler on my 90.

In the mean time I replaced the intercooler on my new 110 again and I can confirm that it is that easy.

Remember to tie the bonnet to something because you wont be able to use the bonnet stay as that will need to come off.

Use the "2 nuts locked against each other" trick to loosen those two threaded pins in the fender on the one side of the bonnet catch plate/crossmember.

Buy a loose hack saw blade to trim down the two pieces of protruding plastic at the bottom of the radiator.

Then slide out the old and slide in the new (it is a bit of a tight fit!).

Easy as that!
Post #328206 4th May 2014 6:37am
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munch90



Member Since: 26 Oct 2013
Location: guildford
Posts: 3558
England 
have the air-de-gassed at a garage , don't just undo the pipes

Last edited by munch90 on 4th May 2014 6:47am. Edited 1 time in total
Post #328208 4th May 2014 6:44am
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ZeDefender



Member Since: 15 Sep 2011
Location: Munich
Posts: 4731
Germany 2011 Defender 110 Puma 2.4 SW Baltic Blue
Regard - yes, I believe it was you - many thanks Bow down

Matt

*Edit* do I really need to degas the aircon if going from above? Tell someone you love them today because life is short.
But shout it at them in German because life is also terrifying and confusing...
Post #328209 4th May 2014 6:44am
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munch90



Member Since: 26 Oct 2013
Location: guildford
Posts: 3558
England 
I would, makes it easy to work on , air con pipes and rad (condenser) a bit fragile ,easy to crack a pipe , if you do crack a pipe its not nice to get a face full of gas

and get it re-gassed and bit of fresh oil ready for summer

nobody really bothers but air-con should be re gassed every couple of years , so not really a waste of money
Post #328210 4th May 2014 6:52am
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ZeDefender



Member Since: 15 Sep 2011
Location: Munich
Posts: 4731
Germany 2011 Defender 110 Puma 2.4 SW Baltic Blue
Good point - I will certainly consider it before banging around in there.
Is refilling the aircon expensive (at the dealer's, obviously). I don't remember ever having it done. Tell someone you love them today because life is short.
But shout it at them in German because life is also terrifying and confusing...
Post #328213 4th May 2014 7:39am
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munch90



Member Since: 26 Oct 2013
Location: guildford
Posts: 3558
England 
land rover will be more expensive , don't know how much where you live , but around here its 40-50 quid if you take it to normal garage

think land rover sent me a "special offer" some time ago and it was well over 100 quid
Post #328214 4th May 2014 7:42am
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K9F



Member Since: 12 Nov 2009
Location: Bournemouth
Posts: 9610
United Kingdom 2008 Defender 90 Puma 2.4 XS CSW Stornoway Grey
When fitting mine the airconditioning didn't have to be degassed at all, just undo the condensor and carefully fit the intercooler. Why spend/waste extra money if you don't have to?

K9F wrote:
I have been considering the installation of an upgraded intercooler for some time. Allisport was the general 'favoured cooler of choice' but the recent pulling of the advertisement off of E-Bay to 'clear the backlog' and the apparent shortage in the UK of decent aluminium TIG welders I decided to extend my search a little further.

A phonecall earlier in the year explained to me that there were some top quality Austrian Engineered intercoolers in the offing and that they would be worth the wait but would come at a premium.

Being a great advocator and believer in 'You get what you pay for' I decided to wait. Serck were available but I resisted the temptation. Made a subsequent call earlier in the week to see if and when they would be available. I was also after a set of silicone hoses as well.

Phonecall made I was informed first batch were in and that (after a little persuasion) a set of stainless steel interconnecting hard-pipes with silicone attachments were possibly to be had too.

12 hours to strip and fit, claret all over the engine bay due to hands being cut to shreds, but am I happy? Hell yes! Great advice and photographs for the fitment from a fellow forum member. You know who you are and yet another BIG THANK YOU to the member concerned.

Bow down Thumbs Up

Photographs speak a thousand words so here's a few against a stock intercooler as comparison. Starting of course with the arrival of a very well packaged parcel.....Worth the wait as excellently engineered and finished. The service from Gary at Alive was top notch too, with update when package was being sent and when arrival could be expected.


Click image to enlarge


Click image to enlarge


Click image to enlarge


Click image to enlarge


Click image to enlarge
 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!!
Post #328233 4th May 2014 9:04am
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munch90



Member Since: 26 Oct 2013
Location: guildford
Posts: 3558
England 
I bet there lots of people fitted without degassing , but I wouldn't , if you ever get a face full of gas and oil sprayed everywhere then some will then wish they de-gassed

also means condenser can be removed out of the way and save any damage to it

pipes can crack quite easy sometimes on the welded joint where the pipe joins the end piece

also like I said good time to get service done on air con and bit of fresh oil ,

funny how some people panick what oil to put in here there and everywhere do it along time before its due or needed then never touch the air con , if you get a pump break up and spread bits of metal round the system its a bl@@dy pain and it will never work as good without full strip down and pumps are EXPENSIVE

Last edited by munch90 on 4th May 2014 10:46am. Edited 1 time in total
Post #328248 4th May 2014 10:19am
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ZeDefender



Member Since: 15 Sep 2011
Location: Munich
Posts: 4731
Germany 2011 Defender 110 Puma 2.4 SW Baltic Blue
Mal - what do you mean undo the condensor? Tell someone you love them today because life is short.
But shout it at them in German because life is also terrifying and confusing...
Post #328257 4th May 2014 10:41am
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munch90



Member Since: 26 Oct 2013
Location: guildford
Posts: 3558
England 
the condenser is the air con rad that's mounted in front of the intercooler ,so the intercooler is fitted between condenser and engine rad
you have to remove some or all of the mounting bolts that hold the frame that the condenser is fitted into
the top bolts on the frame hold the bonnet slam latch panel the bottom bolts to the chassis
Post #328264 4th May 2014 10:52am
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ZeDefender



Member Since: 15 Sep 2011
Location: Munich
Posts: 4731
Germany 2011 Defender 110 Puma 2.4 SW Baltic Blue
Aaah - that's what you call it. I thought there was another bit needed doing Rolling Eyes Tell someone you love them today because life is short.
But shout it at them in German because life is also terrifying and confusing...
Post #328265 4th May 2014 10:57am
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Regard



Member Since: 08 Dec 2011
Location: RSA
Posts: 251
South Africa 2011 Defender 110 Puma 2.4 X-Tech LE Orkney Grey
Really no need to de-gas anything.

There is plenty space if you loosen the bottom 2 bolts holding the AC rad in place.

First time around it took me 3 hours. Second one took me no more than a hour.
Post #328284 4th May 2014 2:44pm
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ZeDefender



Member Since: 15 Sep 2011
Location: Munich
Posts: 4731
Germany 2011 Defender 110 Puma 2.4 SW Baltic Blue
Quick question - I'm trying to get the slam panel off and I'm not sure which way to rotate the studs/bolts. Are they studs, i.e. I should get them out anticlockwise towards the I C or bolts I should screw into the wing?

Cheers
Matt Tell someone you love them today because life is short.
But shout it at them in German because life is also terrifying and confusing...
Post #328533 5th May 2014 2:44pm
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munch90



Member Since: 26 Oct 2013
Location: guildford
Posts: 3558
England 
they studs anti clock and screw them out to ic
Post #328534 5th May 2014 2:46pm
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