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madfrankie

Member Since: 10 Oct 2016
Location: Hertfordshire
Posts: 356

2007 Defender 90 Puma 2.4 SW Stornoway Grey

Possible intercooler split

Morning Ladies and Gents,
My 2007 TDCI 90 SW has developed a loud Whooshing noise (similar to an open window)under acceleration.
and a loss of power similar to a stuck EGR. (Key off then on clears it)

I had a remap done yesterday and had the EGR switched off and blanked (Thinking it was the EGR again!!)
It would seem that this was not the case!
I had intended to have the map anyway (for the obvious reasons) and have also had the speed limiter removed.
The map has made a difference but on the test run the noise was still there.

My mechanic ( Chris @ CSK) has advised that it may be that he thinks the intercooler is split and he will check the fault codes this morning.
So after all that my Question is this....
Should I change/upgrade the intercooler anyway as an improvement to the truck?
If yes is there any particular one that you guy's would recommend?
I am not planning on upgrading the turbo (Unless that turns out to be the issue).
This is an "everyday use" truck and not intended to break the land speed record for breeze block shaped vehicles but I would like it to run as best as it can without too much witchcraft.

Input from you all welcome please.
Thanks
Frank "Of Course, Of course, I ain't asking . I'm telling!!"

31st Jan 2019 9:00am

benniferj

Member Since: 20 Oct 2016
Location: Basingstoke
Posts: 361

If a boost hose hasn't come off then yes there's a fair chance you want to pressure test the intercooler.

I'm a bit shocked that they would go through with performing a map on a completely compromised system though. Surely they'd be fixing that before starting to play with values and get the dyno going! How could it possibly be mapped properly if the turbo isn't sustained proper boost levels?

31st Jan 2019 10:13am

benniferj

Member Since: 20 Oct 2016
Location: Basingstoke
Posts: 361

Also if you upgrade the intercooler, you'd want to map it again to get the best out of it. All you will do is get cleaner EGT temp but no benefit in terms of power from a very expensive intercooler.

31st Jan 2019 10:14am

hank

Member Since: 12 Sep 2016
Location: South Wales
Posts: 2316

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

Have you checked the boost pipe for splits? > 110 XS Double Cab

31st Jan 2019 10:20am

madfrankie

Member Since: 10 Oct 2016
Location: Hertfordshire
Posts: 356

I am planning on going over the engine and system this evening when I get home (Having read lots of the related posts on here) so going to check coolant level , hoses, clean the MAF.

The fault codes are as below:-

DTC P0299
Turbo/Super Charger Underboost

DTC P068A
ECM/PCM Power relay de-energizing too early

DTC P0606
Control module processor internal electronics failure
any one have any clues? "Of Course, Of course, I ain't asking . I'm telling!!"

31st Jan 2019 11:06am

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17603

The first thing I would check on an '07 is that the pipe from the turbo to the intercooler hasn't chafed through on the steering box, a very common fault.

Makes all manner of whistley farty noises when it goes.

31st Jan 2019 11:09am

madfrankie

Member Since: 10 Oct 2016
Location: Hertfordshire
Posts: 356

Added to the list.
Thank you "Of Course, Of course, I ain't asking . I'm telling!!"

31st Jan 2019 11:24am

shropshiredefender

Member Since: 05 Jun 2017
Location: Shropshire
Posts: 834

2011 Defender 110 Puma 2.4 USW Santorini Black

Re: Possible intercooler split

madfrankie wrote:

So after all that my Question is this....
Should I change/upgrade the intercooler anyway as an improvement to the truck?
If yes is there any particular one that you guy's would recommend?
I am not planning on upgrading the turbo (Unless that turns out to be the issue).
This is an "everyday use" truck and not intended to break the land speed record for breeze block shaped vehicles but I would like it to run as best as it can without too much witchcraft.

In answer to the original question - YES - the standard intercooler from Land Rover is O.K. but it has a history of splitting.

I upgraded to the BAS intercooler because it appeared to be properly constructed and much less likely to split. Any enhancement to torque was simply an added bonus.

I have the BAS remap as well as several other performance mods and the overall day to day driving experience is greatly enhanced.

31st Jan 2019 2:10pm

madfrankie

Member Since: 10 Oct 2016
Location: Hertfordshire
Posts: 356

Ok Guys,
So yesterday my shiny new “Alisport” intercooler and “Alive” hoses turned up (Late in the day)
Work light at the ready, I started to remove the old one .
When I finally got the hoses off. I found this

Now I’m no mechanic “but that just ain’t right”!🤪
That would of course account for all the issues I have had.
On the upside?
I have pushed on and fitted the intercooler, blanked the EGR and had an Alive remap
Truck is like a new beast and really quick ( for a defender) on the uptake.

Really pleased.
Thank you all for your advice

Click image to enlarge "Of Course, Of course, I ain't asking . I'm telling!!"

17th Feb 2019 3:32pm

hank

Member Since: 12 Sep 2016
Location: South Wales
Posts: 2316

hank wrote:
Have you checked the boost pipe for splits?

> 110 XS Double Cab

18th Feb 2019 4:48am

madfrankie

Member Since: 10 Oct 2016
Location: Hertfordshire
Posts: 356

Absolutely spot on. "Of Course, Of course, I ain't asking . I'm telling!!"

18th Feb 2019 6:08am

hank

Member Since: 12 Sep 2016
Location: South Wales
Posts: 2316

On the plus side you now have some nice performance upgrades

> 110 XS Double Cab

18th Feb 2019 7:24am

madfrankie

Member Since: 10 Oct 2016
Location: Hertfordshire
Posts: 356

Which I was planning on doing anyway so all good!
As for the upgrade,
I am amazed at how much extra pull the truck now has.
Back to CSK at the weekend for the new map ( taking the intercooler into account)
So fingers crossed for smooth sailing from now "Of Course, Of course, I ain't asking . I'm telling!!"

18th Feb 2019 7:47am

madfrankie

Member Since: 10 Oct 2016
Location: Hertfordshire
Posts: 356

Also just changed the MAF & MAP sensors.
Nothing wrong with them (I think) but while I have blanked the EGR and mapped etc, Figured I would do these too.
Free to a good home if anyone wants to pay the postage?
PM me.
Going to offer them out on the "For Sale" section here as well so first come...... "Of Course, Of course, I ain't asking . I'm telling!!"

19th Feb 2019 8:31am

madfrankie

Member Since: 10 Oct 2016
Location: Hertfordshire
Posts: 356

GONE "Of Course, Of course, I ain't asking . I'm telling!!"

19th Feb 2019 9:25am

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