Thread: Allisport stuff.

Hi Mick

I had no issues installing my Allisport upgraded intercooler into my 300Tdi Defender. It fitted into the exact same position as the old original IC with the mounting pins lining up using the existing rubber mounts.

Are there any noticeable difference between your original radiator and IC with the new ones from Allisport?

Slowly getting there. Pic of the Allisport direct replacement I/C next to the new front mount. Another of it in place, and one of the plus 70mm rad. Turner gas flowed head just went on, new injectors ordered. Once that's all here and fitted it goes off to get the VNT turbo sorted.

I had to remove the lip on the front panel, if you don't it WILL hit the bottom of the I/C. One pic before, one after. I put stick on foam strip along the bottom of the rad and the inside of the panel in case they vibrate together, as you lose the 2 bottom grill screw mounts. Had to cut away part of the support that holds the rad frame to the slam panel to clear the rad filler. The rubber grommet is hard up against the filler. I think it could of been welded in a LOT lower as per the OEM rad, oh well. Looks like it will hold. Also needed to remove a bit of the plastic fan shroud to clear the top I/C pipe. I took more than I needed to, it helped in fitting it back in. For reference, the lower I/C mounts bolt to the 2 brackets on the chassis that bolt to the inner wings. The uppers need holes drilled, and they go through the slam panel, fitted under it. On my car, even after grinding most of the bolt heads down, they still foul the inside of the front panel making it a pain to fit the screws that hold it on. Getting there, slowly.

Had to do a second cut out in the shroud for the lower I/C hose. I wouldn't of been able to fit the lower I/C hose on otherwise. A pic of the new hole needed for the rad filler, and a pic of the shiny new hoses fitted. I think it may also be a good idea to fit the lower I/C hose and secure prior to fitting the rad shroud back in. Might be a bit tight other wise.

Slight problem. I just tried fitting the bonnet and saw that I CANNOT close it due to the striker being only a cm from the top of the I/C and I hadn't even lowered down all the way for the catch to engage. More modifications. Grrrrrr. Had to grind 10mm from the striker which leaves the hook a bit thin. Hopefully it'll be ok.

Came up with a way to reuse the 2 lower grill mounts. This is to prevent vibration. The mounts were straightened out, and the lowers painted. Then mounted to the grill, and the grill fitted. Traced them with a pencil, removed the grill and drilled the holes. The screws were ground a bit shorter, also the orange doohickeys were shortened. There's 7mm between the doohickey and the I/C.

Forgot to put up a pic showing where the I/C mounts bolt to. The I/C needs to have the lower mounts in place when you go to fit it. Rad goes in first, then I/C.

Originally Posted by micksta1973

Forgot to put up a pic showing where the I/C mounts bolt to. The I/C needs to have the lower mounts in place when you go to fit it. Rad goes in first, then I/C.

Thanks for all your information, but on another matter entirely what is the make of your headlights ?