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Harry.O

Member Since: 25 Jul 2014
Location: Warwickshire
Posts: 716

2.2 Defender - Burst Intercooler

We run a fleet of export spec 2.2 Defender 110s in Ghana which are causing a few headaches in respect to the intercoolers and pipework, hoping someone may be able to advise?

Originally the pipes were wearing through and the LR recall style of pipe has been fitted to prevent that. Following on from that the intercooler pipes were blowing off the intercooler connections which have now been secured by doubling up the jubilee clips.

Unfortunately now the inter coolers themselves are bursting, the plastic end tanks split from the alloy centre. Has anyone else experienced this issue?

The engines are in standard tune and are not subjected to off-roading or heavy towing, they typically burst at motorway speeds and not under excessive loads. The ambient temp is normally 30-35*C so the intake temps are on the warm side but that shouldn't be enough to cause these problems. The mechanic has nailed the diagnostics in and nothing seems amiss as far as turbo pressure or fault codes go.

Any suggestions as to what we ought to look for?

Thanks in advance,

Harry

13th May 2016 8:29am

Sadi

Member Since: 23 Jul 2015
Location: Windhoek
Posts: 334

2016 Defender 110 Puma 2.2 Heritage Edition SW Grasmere Green

Burst I/cooler..

Any pics available please?

13th May 2016 6:11pm

ericvv

Member Since: 02 Jun 2011
Location: Near the Jet d'Eau
Posts: 5816

2009 Defender 110 Puma 2.4 SVX Station Wagon Santorini Black

Harry, there is a real and definite solution for all those problems of course. Not cheap, but it works and is reliable. Entreq stainless intercooler pipes for the Puma 2.2 plus a larger Entreq intercooler which certainly in your case where ambient temps as you say usually are above 30°C would be beneficial. Here are two pictures, first one of the intercooler and one of the two stainless pipes of the Entreq kit attached for your 2.2 Pumas, a second picture of the same upgrade when it was done by Entreq last year on my 2.4 Puma. One of my standard rubber 2.4 hoses also had split once, but since last year no worries anymore.

Eric

Puma 2.2 version

Click image to enlarge

Puma 2.4 version

Click image to enlarge

Intercooler detail (same for both 2.4 and 2.2) No plastic part at all at these.

Click image to enlarge You never actually own a Defender. You merely look after it for the next generation.
http://youtu.be/yVRlSsJwD0o
https://youtu.be/vmPr3oTHndg
https://www.youtube.com/watch?v=_GtzTT9Pdl0
https://www.youtube.com/watch?v=ABqKPz28e6A
https://www.youtube.com/watch?v=rLZ49Jce_n0
https://www.youtube.com/watch?v=XvAsz_ilQYU
https://www.youtube.com/watch?v=K8tMHiX9lSw
https://m.youtube.com/watch?v=dxwjPuHIV7I
https://vimeo.com/201482507
https://www.youtube.com/watch?v=ZSixqL0iyHw

14th May 2016 5:04am

Harry.O

Member Since: 25 Jul 2014
Location: Warwickshire
Posts: 716

Re: Burst I/cooler..

Sadi wrote:
Any pics available please?

Afraid I don't have any at the moment, sods law one went yesterday! Next time one goes I'll get a couple of pictures for you. Currently the LR main stealer here has no replacements in stock so the local mechanic has been bonding the end chambers back on which seems to last about 5,000km before it pops off again.

Eric - that is also the solution I was looking at, not a cheap way to fix the issue but at least it means we won't have vehicles stuck on the side of the road

There doesn't seem to be a lot on the internet about this happening but every single one of our 110s have done it now which is a bit odd.

14th May 2016 4:40pm

stevie

Member Since: 16 Sep 2008
Location: Nottinghamshire
Posts: 246

My 2014 110 split its intercooler along the plastic end cap. First time I've had it happen. Car is not tuned but does a lot of towing. It also blew the turbo hose off in the first few hundred miles, twice. Apparently the dealer has had a few vehicles in with pipes that had not been fitted properly at the factory.

15th May 2016 7:32pm

Harry.O

Member Since: 25 Jul 2014
Location: Warwickshire
Posts: 716

That's interesting Stevie, sounds like the exact same problem that we are experiencing, how did they dealer sort the intercooler when that split?

Another intercooler went this morning, looks like a bulk order of uprated intercoolers are required

Harry

1st Jun 2016 7:50am

stevie

Member Since: 16 Sep 2008
Location: Nottinghamshire
Posts: 246

They just replaced the intercooler for a new one of the same spec. Not had a problem since. Sounds as if they need to change your intercoolers for uprated versions. Hope they get it sorted.

2nd Jun 2016 10:08pm

2hooky

Member Since: 30 Dec 2014
Location: cotswolds
Posts: 28

2013 Defender 110 Puma 2.2 DCPU Firenze Red

My 2013 DCPU had the intercooler split around 6 months after it was purchased (new) The dealers did struggle to find what the problem was but in the end they replaced it. It never towed or went offroad. It now has 95k miles on it and has the new engine after the old one seized up on the M6 - it was touch and go to keep it, but glad I have as its now bedded in!!!

22nd Jul 2016 5:31pm

Alien

Member Since: 18 Jan 2015
Location: Bacchus Marsh
Posts: 230

I like the idea of changing the hoses to pipes to reduce the rub point potential.
Another option for the intercooler is one recently released...
http://www.defender2.net/forum/topic47263.html Cheers,
Kyle.

22nd Jul 2016 10:35pm

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