Allisport intercooler installation

[The Cone of Silence]

Morning all.

I wrote an email to Andrew at Allisport asking him for some instructions to install the performance intercooler that I was sent, explaining that I'm a bit new to this sort of mechanical manhandling and not very confident.

As busy as he is after the Christmas holidays, he went to the trouble to write the instructions below for me and I think this shows why they have the reuptation they do - going above and beyond the call of duty.

I shall be tackling the project this weekend and will report back accordingly.

Allow 2-3 hours for installation.
The new intercooler is designed to fit directly onto the original mounts and uses the original hose connections.
You will not require any specialist tools and it is not necessary to drain any fluids.


Remove the plastic grille and extension panel for AC models
Remove top AC frame securing bolt using 10mm spanner
Remove plastic fan top cover
Early models – remove bonnet catch panel to inner wing securing bolts 13mm heads
Late models – use two 13mm nuts locked back to back to remove studs from inner wings
Non AC models – remove two 13mm head bolts securing the bottom of diagonal support bars to chassis
AC models - remove 10mm head bolt in centre of condenser/fan frame
Lift out bonnet catch panel and carefully let it hang on release cable
Remove brackets from inner wings as per pictures 4/5
Remove hoses from rear of intercooler. These will be 6mm hose clips on TD5 and 7mm on Puma models. We use a flexible hose driver here.
Remove 10mm head bolts securing intercooler to radiator
Lift intercooler up and out from radiator.
Now cut two plastic blocks off front of radiator as shown in separate sheet (received with the intercooler showing where to cut). These are for oil coolers when fitted and are not required. We use an air saw but a simple hacksaw blade will suffice.
This is the time to fit new hoses if required as you will have more access available
Fit new AlliSport intercooler onto radiator, you may find sliding the left side in first allows easier fitment.
Now basically reverse the process to put your vehicle back together
Check your bonnet catch lever does not interfere with the new intercooler before closing the bonnet for the first time.
Ensure hose connections are tight before road testing. You may want to tighten hose clamps after having completed a few journeys.



http://www.aulro.com/afvb/attachment.php?attachmentid=55712&stc=1&d=1358465422

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http://www.aulro.com/afvb/attachment.php?attachmentid=55716&stc=1&d=1358465585

[redrovertdi]

When i fitted my 300tdi intercooler[allard-same size] I modified the mounting brackets as my bull/winch bar sits level with the headlight shrouds as most 110 bars do in Australia where as English bars are generally mounted about 3-4 inchs lower, the reason being that with the brackets supplied the intercooler sits to low and is behind the winch and not getting full air flow, my intercooler sits just below the bonnet latch with out touching[be carefull you dont want to close your bonnet and puncture the intercooler], its not difficult to fit at all but use common sense[not that common any more]. I also run the larger allisport radiator.
Richard

[Defendozer]

When i fitted my 300tdi intercooler[allard-same size] I modified the mounting brackets as my bull/winch bar sits level with the headlight shrouds as most 110 bars do in Australia where as English bars are generally mounted about 3-4 inchs lower, the reason being that with the brackets supplied the intercooler sits to low and is behind the winch and not getting full air flow, my intercooler sits just below the bonnet latch with out touching[be carefull you dont want to close your bonnet and puncture the intercooler], its not difficult to fit at all but use common sense[not that common any more]. I also run the larger allisport radiator.
Richard
What sort of difference did you notice with the larger radiator fitted? Any difference at all to the running temps? Makes sense to me to install one as the bigger intercooler restricts the airflow to the radiator, maybe not necessary though...

[redrovertdi]

Its a hard one to answer, my temp guage would always climb on a steep hill, so i fitted a vdo guage. i had a kbx grille that i drilled a lot of holes in because i figured it stopped alot of air- have since cut the guts out of it so now it is a frame with mesh, also run twin thermos from a vt commodore behind the radiator, my engine is fully reconditioned, the block was acid washed and i cleaned out the water jacket and checked with a borer scope that it was clean and replaced all welsh plugs.
car currently runs at 90 degrees normally with a 82 degree thermostat, gets upto 110-15 on a steep hill and comes down after the crest, the fans are set to come on at 92

[Brucet]

We recently ran some non-scientific tests in South Africa. Take a look here:

Defender Puma Intercooler Testing - 4x4 Community Forum (http://4x4community.co.za/forum/showthread.php't=135874)


On the Puma there is a huge difference from standard. Take a look at the video i recorded while testing the difference in acceleration. Although the video makes the road look flat its actually quite a steep hill. We were traveling in single file with airconditioners on in 6th gear, when someone said "go" over the radio.

http://www.youtube.com/watch?v=fzkmz...ature=youtu.be

[The Cone of Silence]

Well, that was a fairly straightforward install and the instructions were really useful. Took me longer than expected due to hose fitting.

A couple of things worth mentioning...

Be REALLY careful of the plastic brackets that the fan top cover screws onto. When fitting the new intercooler I managed to break one of these off because I'm a clumsy oaf.

Hacksawing the plastic brackets is easy enough just with a blade on its own, although it didn't look like an absolutely necessary job - I thought there might be enough clearance without it. Nevertheless, I got rid of them.

I took the opportunity to clean out the radiator and the air con fins with a garden hose until the water was running clear - this took a good twenty minutes. I think I had half the Watagans in there, which may go some way to explaining the overheating issues I've been having.

Silicone hoses
Fitting silicone hoses is HARD WORK! The engine bay is so crammed with components that there's an awful lot of very hard to reach clips and screws....and getting purchase on the hoses to push them onto the housings was difficult. I was lying on the engine at one point, much to my neighbours' collective amusement.

Fitting the hoses to the intercooler first is the way forwards, I think, rather than the engine-side components. This is just to give yourself enough wiggle room fore and aft. Form a side-to--side perspective, there is not a lot of room between the radiator and where the hose clamps onto the intercooler - this was a tough fit but we got there with the loss of a small amount of knuckle skin!

One of my hose clips failed as I was tightening it so I have cable-tied the hose on it thrice and will get a replacement clip for it. Might be worth giving the clips a good clean before you put them back on with the new hose.:blush:

Overall

The performance is very noticeable...and so is the noise - the turbo spooling up and really breathing freely sounds wonderful. I'm impressed.

I need to take the big fella out for a more thorough road test but so far I'd say it's definitely a modification worth doing.

Bobby

[Chilly]

Hey Bobby,

Did you take any photos of the intercooler fitted...would like to have a look, Thanks

Chilly

[tonic]

Hey Bobby,

Did you take any photos of the intercooler fitted...would like to have a look, Thanks

Chilly

Yes, photos please.

[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.

[chook73]

I have a couple of photos of the alisport intercooler fitted

http://www.aulro.com/afvb/members-rides/85537-chooks-defender-110-a-3.html#post1702230

Note that because of the AC on the puma's you dont see too much of them when installed.

[The Cone of Silence]

Thanks Chook, I didn't take any pictures of mine installed.

Did another 400kms this weekend - mostly on bitumen but plenty of dirt and some decent climbs too - I'm still loving the freed-up feeling of it and the better noise form the turbo spooling up.

[Tomo]

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?

[Gibs]

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

[goingbush]

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

https://www.aulro.com/afvb/images/imported/2013/01/71.jpg

https://www.aulro.com/afvb/images/imported/2013/01/72.jpg

https://www.aulro.com/afvb/images/imported/2013/01/73.jpg

[Benny_IIA]

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

[lump_a_charcoal]

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

:eek:

[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?

[AndyG]

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

[lump_a_charcoal]

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!

[tact]

I got my friendly local indie mechanic to do mine. And so glad I did too.

The feller is built like schwartznegger was in his heyday and he still had real issues moving some of the parts about. The studs that you need to remove to get the top bonnet latch plate off (lock a couple of nuts onto the stud and turn) was a total PITA!

[jc109]

So, that's a day gone and I still have work to do.

It's all in place but I have my doubts about the hose clamps. They're in a bloody awkward spot and I'm not certain I've tightened them sufficiently. How much pressure runs through there?

I found I had to cut the passenger's-side bracket in order for it to fit back in place. It fouled on the side of the new unit just outboard of the forward mounting tab (the one with the rubber grommet).

And now everything's back together my damn bonnet won't latch shut. It seems I've not managed to refit any of the original frame and brackets in the right spot. So, back into it again tomorrow I suppose.

If my mechanic had had the time when he had my car last week I'd have gotten him to do it. In hindsight I should have waited until he was free.

And yes, those studs are painful! I came close to threading a couple when trying to refit everything.

Never again! Apart from tomorrow, of course :(

[TimNZ]

Hi JC109, with the bonnet not closing make sure the bonnet pin is not hitting the top of the intercooler, I had to give my one a bit of a trim... Also, I highly recommend fitting bolts/cap screws in place of the studs, makes life much easier in the future!

Cheers,

Tim

[jc109]

Cheers Tim. I'll check that out.

Does anyone know if I need to worry about the hose clamps? They're snug, but not as tight as I'd have them if access was better. What sort of pressure do they see?

[DazzaTD5]

Cheers Tim. I'll check that out.

Does anyone know if I need to worry about the hose clamps? They're snug, but not as tight as I'd have them if access was better. What sort of pressure do they see?

Sometimes doing up hard to get hose clamps needs a small socket, 1/4 drive, extensions etc, its doesnt need to be extreme, but it is turbo boosted pressure, I also look at the clamp position, sometimes by turning it around and accessing it from another direction helps.

drop by say friday and I'll check out your handy work :P

Regards
Daz

[DazzaTD5]

So, that's a day gone and I still have work to do.

If my mechanic had had the time when he had my car last week I'd have gotten him to do it. In hindsight I should have waited until he was free.

Never again! Apart from tomorrow, of course :(

No no..... I'm very glad you tackled the job yourself.....

*Another Defender owner has learnt a wonderful incite into why a Defender can be at times labour costly.

*I encourage all my customers to tackle them "fiddly fun jobs"

*Being reasonably familiar with your vehicle and spanners is nothing but a realistic real world thing when travelling in remote places.

Regards
Daz

[jc109]

Cheers Mate. That's what I've always figured. To be honest, the Meccano-ish nature of these and our DIY tendencies is why most of us tragics buy them in the first place. And I do appreciate learning that little bit more each time. The neighbours might disagree though...

[patclan]

Cheers Tim. I'll check that out.

Does anyone know if I need to worry about the hose clamps? They're snug, but not as tight as I'd have them if access was better. What sort of pressure do they see?

I have an allisport inter-cooler, and ever since I fitted it the turbo hose has blown off regularly, I upgraded the clamp to a proper solid turbo one and it has held better but the other day it popped off and the car went into limp mode, I was only 2k from home so I just restarted the engine and off I went with no turbo but better than limp mode.

I have 2 clamps on it now, the original and the new one, I carry a 8mm & 10mm socket with long extension and a long flat head screw driver all the time, as I said it has blown off a fair bit and I have had to put it back on at the side of the road, it is easier to do with the fan cowling off also so make sure you have a Philips head also :-).

I believe that the metal ridge on the pipe that the clamp goes behind to hold the hose is too small on my intercooler and that is what I am blaming as I seriously could not get the clamps any tighter. Hopefully new ones are better, I got mine in 2011 I think.

Cheers
Pat.

[n plus one]

I have an allisport inter-cooler, and ever since I fitted it the turbo hose has blown off regularly, I upgraded the clamp to a proper solid turbo one and it has held better but the other day it popped off and the car went into limp mode, I was only 2k from home so I just restarted the engine and off I went with no turbo but better than limp mode.

I have 2 clamps on it now, the original and the new one, I carry a 8mm & 10mm socket with long extension and a long flat head screw driver all the time, as I said it has blown off a fair bit and I have had to put it back on at the side of the road, it is easier to do with the fan cowling off also so make sure you have a Philips head also :-).

I believe that the metal ridge on the pipe that the clamp goes behind to hold the hose is too small on my intercooler and that is what I am blaming as I seriously could not get the clamps any tighter. Hopefully new ones are better, I got mine in 2011 I think.

Cheers
Pat.

Hmmm, that's odd. Mine's either a 2010 or 2011 Alli IC and I haven't had the hoses blow in around 5 years. Famous last words though eh? Think I'll check my clamps on the weekend!

[TimNZ]

I have an allisport inter-cooler, and ever since I fitted it the turbo hose has blown off regularly, I upgraded the clamp to a proper solid turbo one and it has held better but the other day it popped off and the car went into limp mode, I was only 2k from home so I just restarted the engine and off I went with no turbo but better than limp mode.

I have 2 clamps on it now, the original and the new one, I carry a 8mm & 10mm socket with long extension and a long flat head screw driver all the time, as I said it has blown off a fair bit and I have had to put it back on at the side of the road, it is easier to do with the fan cowling off also so make sure you have a Philips head also :-).

I believe that the metal ridge on the pipe that the clamp goes behind to hold the hose is too small on my intercooler and that is what I am blaming as I seriously could not get the clamps any tighter. Hopefully new ones are better, I got mine in 2011 I think.

Cheers
Pat.


Maybe worth checking the hose isn't too short, and the engine flexing on its mounts isn't pulling the hose off...? Just a thought.

Cheers,

Tim

[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:cool:.

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:mad:. 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:mad::mad::mad:. 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. :)

[JayBoRover]

Deleted repeat of post.

[tact]

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.

[AndyG]

What brand of hoses are people using, Allisport?

[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/Metal/Clamps/Stainless+Steel+Heavy+Duty+Hose+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

[Beery]

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:cool:.

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:mad:. 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:mad::mad::mad:. 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.

[lump_a_charcoal]

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:cool:.

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:mad:. 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:mad::mad::mad:. 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:censored:.
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:censored:
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.

[TimNZ]

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

[JayBoRover]

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.

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.

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.

[TimNZ]

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

[lump_a_charcoal]

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

Cheers,

Tim

What sizes did you order?

[Toxic_Avenger]

Also known as a T-Bolt clamp.
Often used in fast cars running huge boost.
They don't bend as much as the old norma / jubilee worm drive ones, so you need to get the right size range for your application, then chooch her down hard.
I bought a heap of them for the other car from a hydraulics shop.

[lump_a_charcoal]

Often used in fast cars like Defenders, running huge boost.


Fikst!:p

[Toxic_Avenger]

https://www.aulro.com/afvb/images/imported/2015/09/49.jpg

[lump_a_charcoal]

This one maybe?

[TimNZ]

What sizes did you order?

Sorry, can't remember :( And I'm in the opposite hemisphere to my 110 at the moment, so I can't go look.

Cheers,

[AndyG]

I have some Allisport silicone hoses as spares, will measure the outside diameter. Need to anyhow to order those sexy clamps.

Group buy time?

[AndyG]

Gone on leave today, having a cold beer in Kimbe , airport tomorrow, Brisbane 1700 tomorrow, chilling :cool:
Then
Glenraegh with Mrs hh;)
APT for a day
Fraser Island for 5 :cool:
LROC a day
4wd training for a day
My urologist re prostate cancer :(
And my daughter gave me a dozen fine reds for fathers day that need attention :p

A busy 3 weeks

[lump_a_charcoal]

I have some Allisport silicone hoses as spares, will measure the outside diameter. Need to anyhow to order those sexy clamps.

Group buy time?

The measurements would be great!

Good luck with the prostate too.:(

[AndyG]

Yeah it's a pain in the are, need to organise the chop.

[AndyG]

The measurements would be great!

(

This is the late model 2.2 hoses

Land Rover Defender Puma TD4 2.2 TDCi Hose Kit Late Version blue - AlliSport (http://www.allisport.com/product/land-rover-defender-puma-td4-2-2-tdci-hose-kit-late-version-blue-2/)

Shortest 65 & 75 mm
Middle 60 mm * 2
Longest 55 * 60 mm

If someone finds a local source of the clamps call out

[JayBoRover]

Driving home on the Freeway this afternoon and the intercooler hose blew off again:censored:. Luckily this time I knew there were no hills between where I was and home and only about 20km to go, so I continued in limp mode at around 80kph.
Also luckily this time the silicon performance hoses arrived last week and I bought a set of four 65mm Tee-bolt clamps on Saturday, so I'm actually all set to do the hose swap:thumbsup:.

The only issue now is that I realised while removing the air box to make access easier, that I should take this opportunity to fit a "Nugget Stuff" Puma sealed air intake kit. So I'll order that and then sort out the winch installation and wiring while waiting for the kit to arrive.

This all assumes I can manage to push the clutch in on my old Series 2a with a calf muscle torn in my left leg, otherwise I have to get the D90 Puma going again real quick so I can get to work and the physio. Back to the workshop I go.:spudnikwaving:

[tact]

Guess I am just lucky - never had an intercooler hose blow off from where it's clamped, before or after fitting the allisport intercooler and BAS tune.

Before the intercooler/tune was fitted: one original hose split on me (intercooler to manifold) and replaced under warranty, and the recall was done on another original hose (the one from turbo to intercooler).

I did ask about a silicone hose set when ordering the intercooler but was told that if I had the latest updated hoses from LR they are good enough.

When the intercooler/tune was ordered the above two original hoses had been updated by LR already so didn't bother with the silicone hose order. Local indie mechanic did the intercooler install for me with the ordinary hose clamps.

Have done ~5000km since. Not a lot I grant. But hoses blowing off are (touch wood) just not a feature of my experience for the 43,000km since new two years ago.

[JayBoRover]

Guess I am just lucky - never had an intercooler hose blow off from where it's clamped, before or after fitting the allisport intercooler and BAS tune.

Before the intercooler/tune was fitted: one original hose split on me (intercooler to manifold) and replaced under warranty, and the recall was done on another original hose (the one from turbo to intercooler).

I did ask about a silicone hose set when ordering the intercooler but was told that if I had the latest updated hoses from LR they are good enough.

When the intercooler/tune was ordered the above two original hoses had been updated by LR already so didn't bother with the silicone hose order. Local indie mechanic did the intercooler install for me with the ordinary hose clamps.

Have done ~5000km since. Not a lot I grant. But hoses blowing off are (touch wood) just not a feature of my experience for the 43,000km since new two years ago.
I have the updated hose on the turbo side. Interesting to see, when I removed it tonight, that you can see where the touch points are. The sleeving that LR have put over the external spring wrap is even worn through slightly in two places.

Less interesting to see is that the Tee-bar hose clamps I bought don't fit:(. I measured the hoses at 65mm OD so bought the clamps that said they were 64mm. Doesn't make sense to me that they would size clamps that fit on the outside of hoses by the internal hose diameter, but that seems to be the case because the 64mm clamps are still loose when done right up on the 65mm hose. Grrr:mad:. I now have to leave the job half done to get smaller clamps.

[sandu]

hey guys,
I received my Allisport intercooler last week and yesterday installed it.
BUT, I noticed that I am not able to fit back the diagonal support brackets in front of intercooler.
Anyone knows how to proceed further?
Car: DEF, TD5, NON-A/C

[Beery]

I dont know the answer to your question, but of you're on facebook, have a look on the BAS Remaps or the Bell Auto Services page (two different pages) ans search through the photos. From memory there are some good ones of a non A/C Allisport install on there.

[sandu]

I dont know the answer to your question, but of you're on facebook, have a look on the BAS Remaps or the Bell Auto Services page (two different pages) ans search through the photos. From memory there are some good ones of a non A/C Allisport install on there.

thank you, I contacted also Allisport..
it seems that I didn't receive the spacers to fit the brackets with new intercooler.. I will make them at a local workshop