Thread: Allisport intercooler installation

Originally Posted by JayBoRover

Deleted repeat of post.

Sad (and scary!) to hear of your issues. I have done a few quick runs to Singapore and back with the 170hp tune loaded. Includes some extended serious high speed runs. Never had my intercooler hoses blow off.

What brand of hoses are people using, Allisport?

Not sure if it is any use to you guys, but I have a mate who rally's a celica with some serious boost and he only uses this style of hose clamp.

http://themetalcompany.co.nz/shop/Me...Clamp+304.html

I stole one off him one time, and you can get them damn tight and they are easy to use.

Edit: apparently also known as mikalor clamps

Sent from my Nexus 4 using AULRO mobile app

Originally Posted by JayBoRover

Well I headed off from home (in Perth) to Sydney today, and only got 150km when the turbo pipe blew off at the drivers side intercooler connection. I was towing a loaded, enclosed trailer and the D90 was fairly full to window sill level and the roof tent fitted to the roof rack. The little thing hauled arse up Greenmount hill, blowing past a V8 Cruiser in the acceleration to 80kph at each of the speed limit change signs. Very impressive that 170BHP BAS2 re-map.

So a half hour on the roadside to refit the hose, do the clamp up again, reset the ECU faults with my phone APP via the diagnostic magic box and headed off ? this time for about 2km. Okay, time to get serious. Pulled the hose right off and cleaned the inside of the hose and the outside of the intercooler connection. I figured some oil film or something must have been blown out with the air the first time it blew. Tightened the clamp up with a 3/8" drive socket this time, instead of the 1/4" drive of last time. Gave it a fair twist.

Lasted a bit longer this time ? another 50km or so. This time I pulled the whole intercooler out (yes, on the road verge!), wire brushed (yes, I carry a lot of tools) the intercooler connection and thoroughly cleaned it. Put it all back together (twice because I forgot to refit the plate on the passengers side with the clip for the bonnet support arm and then thrice because I seem to have moved the radiator and couldn't get the plate mount holes to align). Tightened the clamp a touch too much and felt it slip a notch, so tweaked it up again.

Turned around and headed back for home, setting myself a limit of 230kPa manifold pressure. Got home okay, with no further blow-outs, but a long day for no result. Now I have to figure how to get my trailer with Dakar motorcycle, spare wheels, tyres, fairings, exhaust and boxes and boxes of parts to Sydney for the new owner. Step 1 will be to order some silicon intercooler hoses and a bunch of clamps that NASA haven't even invented yet!

I also thought on the way home to stop at a servo so I could download the original ECU map, figuring it might take some pressure off me monitoring the intercooler pressure on the drive home. I selected "yes" for all the "are you sure" and "make sure you read the manual in case the reload fails" messages and then panicked when the display came up with "toggle the ECU fuse". Faaarrrrkkk. What fuse? The picture on the inside lid of the dash fuse box doesn't have "ECU" anywhere. None of the fuses under the drivers seat say "ECU" either. I pulled out all the fuses with an engine picture but none did anything. I turned the key off and pulled it out, then put it back in and turned it to ACC. I'm not sure at what point the display then said "re-load failed". Thank God it hadn't wiped the ECU program. So I continued my journey with my phone constantly displaying the boost pressure, and limited me to around 90kph at 230kPa pressure - which was about 60% calculated torque load and around 33% throttle position. Gotta love that little diagnostic magic box!

So my 10.5 hr day in the mighty 90 involved only going about 250 kms East and then turning around and driving that back home again. Probably 5 min's of grinning like a mad-man as I raced up the hills, 3 hours of driving normally, 4 hours with my head under the bonnet tearing the skin off my hands and flicking flies out of my eyes and ears, and 3.5 hours driving back very sedately at around 90kph - very boring. I hope the next attempt goes better.

That's a royal pain in the @rse!

My driver's side hose keeps trying to come off as well.
I moved to Darwin a few weeks ago and after the 3600km drive, I was checking things over when I noticed the hose had pushed about 40mm back. So I loosened the clamp and pushed it right back on and tightened it up as much as possibly. Thought it would be ok.

Checked it again yesterday and its done it again!

I might have a look at putting a second hose clamp on.

Originally Posted by JayBoRover

Well I headed off from home (in Perth) to Sydney today, and only got 150km when the turbo pipe blew off at the drivers side intercooler connection. I was towing a loaded, enclosed trailer and the D90 was fairly full to window sill level and the roof tent fitted to the roof rack. The little thing hauled arse up Greenmount hill, blowing past a V8 Cruiser in the acceleration to 80kph at each of the speed limit change signs. Very impressive that 170BHP BAS2 re-map.

So a half hour on the roadside to refit the hose, do the clamp up again, reset the ECU faults with my phone APP via the diagnostic magic box and headed off ? this time for about 2km. Okay, time to get serious. Pulled the hose right off and cleaned the inside of the hose and the outside of the intercooler connection. I figured some oil film or something must have been blown out with the air the first time it blew. Tightened the clamp up with a 3/8" drive socket this time, instead of the 1/4" drive of last time. Gave it a fair twist.

Lasted a bit longer this time ? another 50km or so. This time I pulled the whole intercooler out (yes, on the road verge!), wire brushed (yes, I carry a lot of tools) the intercooler connection and thoroughly cleaned it. Put it all back together (twice because I forgot to refit the plate on the passengers side with the clip for the bonnet support arm and then thrice because I seem to have moved the radiator and couldn't get the plate mount holes to align). Tightened the clamp a touch too much and felt it slip a notch, so tweaked it up again.

Turned around and headed back for home, setting myself a limit of 230kPa manifold pressure. Got home okay, with no further blow-outs, but a long day for no result. Now I have to figure how to get my trailer with Dakar motorcycle, spare wheels, tyres, fairings, exhaust and boxes and boxes of parts to Sydney for the new owner. Step 1 will be to order some silicon intercooler hoses and a bunch of clamps that NASA haven't even invented yet!

I also thought on the way home to stop at a servo so I could download the original ECU map, figuring it might take some pressure off me monitoring the intercooler pressure on the drive home. I selected "yes" for all the "are you sure" and "make sure you read the manual in case the reload fails" messages and then panicked when the display came up with "toggle the ECU fuse". Faaarrrrkkk. What fuse? The picture on the inside lid of the dash fuse box doesn't have "ECU" anywhere. None of the fuses under the drivers seat say "ECU" either. I pulled out all the fuses with an engine picture but none did anything. I turned the key off and pulled it out, then put it back in and turned it to ACC. I'm not sure at what point the display then said "re-load failed". Thank God it hadn't wiped the ECU program. So I continued my journey with my phone constantly displaying the boost pressure, and limited me to around 90kph at 230kPa pressure - which was about 60% calculated torque load and around 33% throttle position. Gotta love that little diagnostic magic box!

So my 10.5 hr day in the mighty 90 involved only going about 250 kms East and then turning around and driving that back home again. Probably 5 min's of grinning like a mad-man as I raced up the hills, 3 hours of driving normally, 4 hours with my head under the bonnet tearing the skin off my hands and flicking flies out of my eyes and ears, and 3.5 hours driving back very sedately at around 90kph - very boring. I hope the next attempt goes better.

I experienced similar, but instead of the hose coming off the turbo, it just ruptured.
I replaced the OME ones with silicone, and then the 4th hose that goes onto the manifold (which wasn't included in the kit) ruptured.
This time I reflashed it to stock, and sent it to LR for a warranty job, which they happily did. They also replaced the recalled turbo hose as well.
Just after they replaced it, it blew off the intercooler again.
Luckily it was easy to refit, and double clamp, but I'm waiting for the turbo end to blow off again also. When it does, I'll double clamp it too.

I also only run the 150hp tune now, to save hoses popping off.

Regarding the "toggle ECU fuse", I did the same thing - pulled every fuse I could find, and nothing ... Then I just turned the ignition on, and it went away
It is just a confusing way of saying the ignition isn't on I guess.

Good luck, and when you replace the hoses, make sure you get the post recall kit, not the pre recall kit like I did. Post recall is a single hose from turbo, pre recall is two hoses and a steel pipe.

From spying on the ecu with the torque app max boost pressure is the same with the standard and 170hp tunes, (22.5psi). I've run a total of about 60k klms with two 2.2 Defenders, both with the Allisport Intercooler and BAS tune and have not had any issues with the stock hoses coming off, just being too short, (which was fixed via JLR recall). I have however changed the hose clamps to the type shown in the link a few posts ago. I strongly recommend checking the hoses are not pulling on the intercooler, or the end tank(s) will split.

Given the issue with them rupturing I think I'll be upgrading them to silicone sooner than I planned though.

Cheers,

Tim

Originally Posted by tact

Sad (and scary!) to hear of your issues. I have done a few quick runs to Singapore and back with the 170hp tune loaded. Includes some extended serious high speed runs. Never had my intercooler hoses blow off.

I had also done a few good speed runs, including smashing it up some passing lane hills, and never had a problem. The occasions yesterday when the hose blew off repeatedly was fairly heavily loaded and extended periods of climbing at 100kph. I think the high constant load is the precursor.

Originally Posted by AndyG

What brand of hoses are people using, Allisport?

Mine are the factory hoses but the hose that keeps blowing off was the one they fitted a bracket to under warranty to prevent it touching the steering or something like that. It's too short but the big issue for me is the way it is shredding apart and splitting at the end. The clamp fitted has tabs to locate it at the end of the hose and makes it difficult to locate at the flare in the alloy tube.

Originally Posted by BadCo

Not sure if it is any use to you guys, but I have a mate who rally's a celica with some serious boost and he only uses this style of hose clamp.

http://themetalcompany.co.nz/shop/Me...Clamp+304.html

I stole one off him one time, and you can get them damn tight and they are easy to use.

Edit: apparently also known as mikalor clamps

Perfect! That's the exact type of clamp I was thinking of. I've used them before and they are top stuff! Cheers for the reminder.

Originally Posted by JayBoRover

Perfect! That's the exact type of clamp I was thinking of. I've used them before and they are top stuff! Cheers for the reminder.

I got my ones from either Couplers or L&T Venables in Malaga

Cheers,

Tim