Thread: Leaky Intercooler

Yeah, that makes sense. If it is metal fatigue, as these cars get older, we will see a lot more of this... hope it doesn't occur too soon on mine.

Cheers - Gav

I finally got round to buying a new replacement intercooler. i bought a Britpart one from LR Direct in the UK. It arrived in under a week and is identical to one that burst and has all the branding etc (Behr). And third price of a Land Rover one which I suspect will be identical. Fitting this was obviously a lot easier second time round. To fit the I/C I slide it in from the the front left wheel arch and just raised the suspension to max and removed the washer bottle, didn't even take the wheel off. The only issue was the 1.5 hrs to refit the fan, yes I know it's lh thread but the combination of big hands and small space doesn't work well. I had a couple of self pipe removals at the manifold end which I cured by removing all the oil from the pipe and fitting 2 hose clamps.
All good so far.

Adrian

I haven't as yet looked in way of intercooler on my TD6, but can you advise if any spare space?
Thinking along "bigger" I/C? Can we go longer? higher? thicker?
What are dimensions of the original core?
I've got a big chunk of good 65mm thick core somewhere in the garage: was originally destined for TD5, but maybe NOT!

Hi Donrover0
I didn't check for extra space but it is a tight fit. I did not want to remove any of the other radiators, water, oil, a/c etc to have a look. As these are the same i/c as fitted to the BMW 730D and other BMWs there may be a larger aftermarket version available. I did have a spec sheet with dimensions for the BMW version but cannot find it. Search the internet.
J Fearn Engineering in the UK used to make/fit a modified i/c along with other mods but no longer do this.
There is a bit of space under the bonnet in front of the wheels on the TD6 which did have me thinking.

Adrian

Thanks,
I did eventually find dimensions of the genuine article, but wasn't sure about surrounds.
I'll be home with the car about 2 weeks, so will have a good look then.
L322 intercooler core is 105mm thick, so my big chunk of 65mm no good here!

Hi Don, I wouldn’t bother with a larger IC.

I’ve taken readings on mine and the stock IC does a great job, I posted details up here somewhere, and mine runs only a few degrees up on ambient with the only exception being when the throttle is pinned very hard and boost climbs over 20psi, we did some silly tests on the steep pinch near the top of mount Glorious. See if I can dig the details up.

Just figure there other places $ can go

Hi Harlie,
You are most probably correct- once I saw the dimensions of the std intercooler, I thought sounds ok.
I have to sort out my gearbox problems before I think of "improvements" of performance. If new gearbox , 5L50E (500Nm rated) works out at reasonable cost, then I MIGHT ( read probably will) chip the fuelling .

Don, I’m following your trans works with interest (pls keep it coming), My truck (late 04 @ 158) has no signs of trans problems, fluid changed twice now (110 & 150), both times completely clean but like many here, I want to have a plan.

Already given mine the fuel mapping treatment and according to many that will just accelerate my possible issues, It’s a nice truck with 500-520nm – our readings were taken just after new fuel map was loaded.

Personally I believe if you’re going to have issues – you’re going to have them tuned or not… Mate at Tweed, who has owned his ’04 since new changed his trans fluid recently (@ 98km) after much nagging from me, it was unbelievably dirty and contain heaps of particles. His is completely stock. Truck is much smoother now…

Mate, let me know if you want a hand....