Thread: Help in fitting Full Size Intercooler in Disco 300tdi

never fitted one. are you sure it is correct one?

all i can offer is to consider me first in line if you wish to sell it.

thank you.

Originally Posted by Cap

.... I have very basic fitting instructions which seem to indicate I need to hole saw two holes on the plate next to the left headlight for the pipes to go through, which of course is where the power steering reservoir sits also. So I am hesitant to do any mods unless I am 100% certain with clear instructions/photos.

...

Which is at odds with the info on the Allisport website ...

.... "Fits in front of AC condenser with no vehicle modifications required." ....

Not sure what they deem to be 'vehicle modifications' but I'd have thought cutting great big holes in the bodywork would be!

I had some through flow issues with mine a little while back(mine has AC too), but it just turned out that the black plastic panel that sits flat under the AC condenser HAS to be there for best ram effect.
Remove this and air seems to get pushed down and under, instead of through the radiator.
Mine's auto, and this black plastic panel sits on the trans cooler lines when all the clips have broken off(as they most likely will). SO the plastic panel rests on the hot trans lines, it melts(like mine did) and becomes semi useless.
I made a flat tin sheet panel to scoop a bit of air under the bullbar lower edge.
Previous heating up issues with AC on on a hot day solved. :th3:

From memory there's still a bit of empty space under the pwr steer reservoir, so maybe after holesawing it can still stay located in situ with the hoses running under it

If it does needs moving, you'd have thought Allisport would have supplied a bracket to relocate it anyhow!
But then again having dealt with Allisport myself, I know that they're not particularly 'switched on' .. and I'm surprised you got your product and not an IC for a totally different vehicle!

.... like they did for me ... 3 times! I gave up in the end and just self-modded the bits they did send me which amounted to 2 times what I actually ordered .. but basically all wrong.

As for if the added IC in front of the rest of the system(I'd be more worried about the AC condenser myself) .. if you remove the IC, at the least it'll also give you the option to add a larger radiator too.
With the right hose setup, maybe even one out of a V8 using the now full width of the opening.

If you look at pictures on their website it looks like the hoses come from 90degrees next to headlight. Not sure but i think there’s panel work there which would assume the holes need to be cut.

This is correct Val, and when I placed the ic in position it definitely needs holes, and this worries me. Not having any templates to go by is hard.

Thanks Arthur, I too found that statement ridiculous. I found another vid of a IC that has the pipes run through the gap the original IC was in, which makes sense as this is where the pipes would be fitted. So maybe the auto has a different design to my manual, it almost looks like mine is a defender if, but its not.

Below is a pic I found off the web showing exactly the mod required next to headlight



On the radiator note, is the V8 replacement a good option for more cooling (assuming ic not there), given I tow also?

Originally Posted by Cap

Thanks Arthur, I too found that statement ridiculous. I found another vid of a IC that has the pipes run through the gap the original IC was in, which makes sense as this is where the pipes would be fitted. So maybe the auto has a different design to my manual, it almost looks like mine is a defender if, but its not.

Below is a pic I found off the web showing exactly the mod required next to headlight

.....

Auto has the trans cooler down low up front .. so I assume it has to be removed for this IC to fit .. hence why they specifically state (manual) on the sale site.

Also note in the pic you uploaded that the fitting of that IC still seems to retain the pwr steer reservoir in the same location too.
Dunno if that's fully fitted tho, ie. have the pipes been connected, etc. but if they haven't moved it about for the install, then it seems ok, and hoses pass well underneath to retain its original spot.

Originally Posted by Cap

This is correct Val, and when I placed the ic in position it definitely needs holes, and this worries me. Not having any templates to go by is hard.

when i've talked to allisport in the past they have been very helpful. perhaps get in contact with them, i am sure they can provide you with everything you need to make it happen.

if you decide it's too hard let me know. I wouldn't mind getting my hands on one. but i am sure that with advice from allisport it's probably not too hard for you to fit.