Thread: Allisport I/C

Allisport double core into '97 300 TDI Defender with Aussi air conditioning.
It's in and going. This is how I did it. It did not just drop in as shown on Bushman83 (Brett's) video, like a piece of toast into a toaster. I had to remove both the folds from the side panel on the radiator frame (Allisports instructions are ambiguous as to one or both) Remove both along with the locator tag for the fan shroud. I also cut a sliver off the top of the fan shroud and a notch from the bottom, with a hot knife. Photos show;
Photo #1; big intercooler touching the air conditioner condenser. ( centre of pic)
Photo #2 White texta mark for cut to top radiator frame to allow top pipe to fit.
Photo #3 Shows how I bent the condenser support around the big intercooler.
Photo #4&5 Shows holes adjusted in condenser support frames. left and right. In photo 10 you'll see I didn't need as much movement on the top onside support frame.
Photo #6 Shows trim line to bottom of condenser to clear righthand strut mount.
Photo #7&8 shows a trim marked for the bonnet latch rail.
Photo #9,shows spaced out support strut (10mm)
Photo #10 shows how the radiator has moved toward the engine and the top radiator steadies that I beat out to bridge the bigger gap.
Photo #11,12&13shows the revolting old intercooler, but clean inside.
The bonnet latch does not strike the top of the condenser, and there's clearance between all the components where there should be.
I've now had the pump tweaked by Brad Pollard at KLR south Windsor, and I'm very very pleased. Brad certainly knows his stuff. The Pollards of this area seem to have a very severe Land Rover infection, I'm delighted to say.
Don.

More photos of my double core intercooler install. See my previous post for the key.
Don.

More photos of my double core intercooler install. See my previous post for the key.
Don.

well done. I tried a few of the same things such as spacing the passenger bonnet catch support rod at the bottom, but with the evap moved forward as far as I could it caused the evap fan to hit the grill. upon measuring I still had at least 15mm of space needed. I guess not a single Defender is the same? be rather keen to see a dyno sheet though.

Micksta1973, if that dyno question is aimed at me, sorry, I didn't dyno it before or after. have a look at bush mans vid of his one. It's a 200 TDI and without air con.There are dyno results.
Don.

So for those who say the thicker intercooler didn't make a big difference, should you have gone bigger or gone with the smaller one that fits in the original space?

Jeff

Picked mine up from the mechanic this afternoon. He said he had a few issues but made a couple of brackets and got it in. SHMBO was following me home in the wet and I was not allowed to get to far away but got a few squirts in, just brilliant.


So far we have only adjusted the fuel pressure and not done the whole adjustment as suggested by Alli, see how we go.


I did get to try a few things on the way home, like accelerating in 5th up hills and going round 2nd gear corners in 3rd, all worked better. For me it's about better towing and am picking up new Jayco Hawk tomorrow, so I will be interested to see how it goes.

Originally Posted by Jeff

So for those who say the thicker intercooler didn't make a big difference, should you have gone bigger or gone with the smaller one that fits in the original space?

Jeff

I would personally recommend doing the pump mods and see if you are happy with that. I found the double core intercooller only brought down the EGT's which made it safer to run higher boost, but you need a boost controller to get up there (16 psi+).