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Marius

Member Since: 21 Dec 2010
Location: South Africa
Posts: 231

2011 Defender 110 Puma 2.4 SW Keswick Green

New improved BAS intercooler Fitment help needed

So I started the fitment this morning. I knew those 4 bolts were going to be issues, but I didnt realise it was THAT difficult to get them out.

Anyways I'm having ssues fitting the intercooler.

For previous coolers one has to cut away thoe 2 plastic blocks. Do you still need to do this - It doesnt seem so?

I cant get the cooler in place no matter how hard I try. It rests on mounts but I cant get the right one in. Either the pipe opening outlet fits into the space next to the radiator but then the pin isnt through the hole. It doesnt seem to me in any case possible to get the intake pipe nect to the radiator and at the same time the pin through the hole?

Anyone fitted one of these recently to a 2.4?

Last edited by Marius on 26th Jul 2014 7:04pm. Edited 2 times in total

26th Jul 2014 2:03pm

K9F

Member Since: 12 Nov 2009
Location: Bournemouth
Posts: 9610

2008 Defender 90 Puma 2.4 XS CSW Stornoway Grey

Marius,

When I fitted my intercooler which may be a different one I believe, I had to open up slightly two of the holes on the intercooler. Only by a millimetre or so, it didn't impact on the security as there were rubber grommets that fitted in the holes. I could get the intercooler to fit but only without the grommets, opening up the holes allowed me to fit with the grommets.
Don't know if this is any help but it depends on how far out it is? 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!!

26th Jul 2014 2:09pm

Inigo

Member Since: 13 Nov 2011
Location: Kent
Posts: 617

2012 Defender 110 Puma 2.2 USW Orkney Grey

My local independent fitted mine badly. Afterwards, I got instructions from Allisport and fitted it properly.

Not quite sure how to post links, but it is in my gallery here:https://www.defender2.net/gallery/albums/u...-%20AC.pdf

26th Jul 2014 3:25pm

Marius

Member Since: 21 Dec 2010
Location: South Africa
Posts: 231

Im attaching 2 fotos. Hope they show...

My radiator has a k8nd of cut out for the cooler outlet tube. I can get the tube through this but then I cant manure it up any more to fit the pin.

Click image to enlarge

26th Jul 2014 3:49pm

Marius

Member Since: 21 Dec 2010
Location: South Africa
Posts: 231

Ok finally got sorted. Had to reduce the length of the right side pin by 2mm.

27th Jul 2014 11:08am

bell-auto-services

Member Since: 08 Jul 2007
Location: North Yorkshire
Posts: 2232

2013 Defender 110 Puma 2.2 USW Orkney Grey

Hi

Sorry ive not seen this post until now, ive been at a the Billing show and had myD3 die on the way home so was a long night

You do need to remove the lugs on the radiator to allow the cooler to sit fully flush to it, without doing it they are a fight on the radiator brackets and so do need removing to allow correct fitment of the cooler.

Once the lugs are removed I offer the cooler up to the right hand side locating hole first and then to the left last.

Thank you Inigo for posting the Allisport pdf.

Regards Pete

28th Jul 2014 8:49pm

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