Allisport I/C

[micksta1973]

Well after spending lots of money on an Allisport double core I/C, I spent the weekend pulling everything out of the engine bay that was in the way to make it fit. I then thought I'd simply just pop the new intercooler in along with the modified bracket. put it all back together, an voila. Not so. I have factory A/C (1995 Tdi 110) which I was assured wouldn't be a problem, as the I/C was designed to fit with this. The I/C hits the evaporator, I then tried spacing that forward, which helped a bit, but then I found the captive nuts on the frame where the evap bolts to rubbed on the side of the I/C, plus the frame rubbed on the top end tank. So, to cut it short, there is absolutely no way this will fit in my car, short of owning a fabrication shop to make a new front end radiator I/C mount. Bit of a bummer I must say after hearing that they can make quiet a difference.

mick.

[460cixy]

I think the Aussie a/c is different to the uk a/c

[Wicks89]

Dude it can be done! The double core intercooler is a fair lump but the benefits will outweigh the negatives with this thing. Bushman83 (Brett) installed one on his tdi so you can check his thread in projects and tutorials for some photos etc on how he put it all together. I went the straight replacement and it still required some mods in my old tdi, but then it's performance made it so much more drive able.

Best of luck!

[Scouse]

I think the Aussie a/c is different to the uk a/cYep, 'factory' A/C on a 1995 Defender is an AMC kit, fitted once the car arrived in Australia.

[Presto]

Hi Mick,


I've been through exactly the same thing, and although the service from Allisport is second to none, Andrew could only confirm that this A/C unit is different to the UK version, so fitment had not been checked. His advice was to try elongating the holes in the base plate so the intercooler sits further back, but I wasn't keen on the idea. Instead, I modified the bracket that the A/C condenser mounts to, pushing that forward to give me about 2/3mm clearance with the I/C. Seems good so far! :)


Regards
Grant

[Presto]

On the performance side of things, I had fiddled with the pump prior to fitting the double core I/C, and found that the pump mods made a much greater difference than the DC I/C over the std unit. All it seemed to do is reduce the EGT's a little which will allow a little more boost, but not as big a difference as just the pump mods.

[micksta1973]

Absolutely no way can I fit it. The evap cannot move froward more that 5mm or so due to the support rods for the bonnet catch, plus the evap fan would then hit the grill. The only way I could think of was to cut the locating pins off (which is a pain as they are welded from the inside of the end tanks) then re weld them to space the I/C further into the engine bay. This would then mean major cutting of the fan shroud, as well as the I/C hitting/rubbing against the one piece rad hose. In the end I really didn't expect the car to turn into a rocket. I knew that when I bought it.

[Presto]

I got the same conclusion, but somehow managed to find the space by loosening everything off and modifying the condenser bracket. I had to go at the fan cowl pretty hard too. Even if you do decide not to fit the I/C, I highly recommend doing the pump mods, as although it doesn't turn it into a rocket, it does make a HUGE difference!

[Don 130]

I too have found the installation of the double core intercooler is fouled by the australian air-con. I'm trying to find a solution this weekend. Stand by.
Don.

[130camper]

I got my uprated Allisport i/c to fit. Certainly its not a simple old out new in job.
Did mine over 12 months ago so can't remember the exact details and measurements, but very pleased I persisted with the fitting, the results together with the pump adjustments were definitely worth the effort.


Did not make any changes to the new i/c
I moved the passenger side of the a/c evaporator forward on to some new brackets, and I think some spacers on the drivers side.
I cut the piece of the plastic radiator shroud off that goes over the old i/c. Then using thin aluminium sheet made up a curved piece to continue the shape of the remaining shroud and pop riveted on to the shroud, so that the fan was still enclosed to suck air through the radiator.
On mine there is no shroud on the engine side of the new i/c.
When I finished mine I had to bend a Z in the bonnet secondary catch and cut the top radiator holding plate for it to go through so that it didn't hit the a/c evaporator.

[noogie]

I had mine fitted by my mechanic and he said that he had to make a few adjustments inorder for it to fit. One thing I have to be careful of now is that the bonnet catch doesn't hit the top when closing bonnet.

I have to pull the catch forward a bit then close the bonnet.

Rapped with it though.

[Don 130]

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.

[Don 130]

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

[Don 130]

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

[micksta1973]

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.

[Don 130]

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.

[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

:rocket:

[tonic]

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.

[Presto]

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

:rocket:

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+).

[DeeJay]

Whilst mine is a TD5, I just bought a generic one & made it fit. The easiest option was to shift the bonnet supports to the side & strengthen the top bar put in a lower bar. Not a great photo.


https://www.aulro.com/afvb/images/imported/2014/05/1251.jpg