Thread: Allisport intercooler installation

Originally Posted by Benny_IIA

One thing I found out was that the NON ac cooler can be fitted to aus spec ac cars (longer nose).

Its 20mm thicker so a fare bit more cooling.

Very Interesting!
So the AUS spec pumas have a longer nose? Therefore the NON AC that allisport make will fit?

Would that include TD5's ? I'm about to order one for my 2001 130 TD5, be nice to get the extra width.

I would not fit the non A/C intercooler into an A/C Td5

just me, but I think that 20mm gap is important, esp for cleaning the muck out.

I think the A/C intercooler is such a huge improvement over standard you'd hardly notice an extra 20mm anyway,

some pics of mine, orig Td5 EU3 compared with Allisport

Originally Posted by Tomo

Very Interesting!
So the AUS spec pumas have a longer nose? Therefore the NON AC that allisport make will fit?

yep, fits fine still a decent gap between cooler and ac con

I fitted mine tonight, and I can confirm that it does fit upside down.

Made a start on installing mine yesterday and what a mongrel of a job it is turning out to be.

Firstly, for others yet to attempt a DIY, the driver's side bracket from photos 4&5 above also holds your bonnet stay, so make sure you have something rigged to stand in for it.

Secondly, are you guys sure you don't need to remove the fan and A/C gear from in front of the intercooler in order to fit the new one? I can't get my replacement to sit right.

And finally, how the HELL do you get the hoses back on? On the driver's side in particular there's barely enough room for your fingers let alone your forearm to allow enough force.

Everyone else on here seems to find this an easy job, so what am I doing wrong?

There's another job i will contract out, im too old & inflexible for this stuff, (and possibly fat)

Originally Posted by jc109

Made a start on installing mine yesterday and what a mongrel of a job it is turning out to be.

Firstly, for others yet to attempt a DIY, the driver's side bracket from photos 4&5 above also holds your bonnet stay, so make sure you have something rigged to stand in for it.

Secondly, are you guys sure you don't need to remove the fan and A/C gear from in front of the intercooler in order to fit the new one? I can't get my replacement to sit right.

And finally, how the HELL do you get the hoses back on? On the driver's side in particular there's barely enough room for your fingers let alone your forearm to allow enough force.

Everyone else on here seems to find this an easy job, so what am I doing wrong?

It isn't a walk in the park, but it is definitely DIYable.

I removed the bonnet completely, which made accessing the inner workings easier.
I didn't have to remove any of the AC stuff either, but I did unbolt it fomr memory, just to allow some movement.

As for the hoses, they are quote hard to do!
I just put them into a bucket of hot water to soften them up, and eventually got them on, after lots of swearing.
You can undo the fan shroud to make more room, just bend it out of the way.

It does require a fair bit of agility and hand/arm strength, as well as being able to hold your tongue in the right position whilst swearing.

Good luck!