Fitting td5 Intercooler to 300 tdi, Thoughts

[Bazzle218]

I have a 110 ute and will be fitting a td5 intercooler ( Because i can)
As i have aircon, has anyone given thought to, removing the original intercooler and fitting the evaporator for the aircon in its place. Thus freeing up the space in front of the radiator for the intercooler. the evaporator will then have the full benefit of the shroud to aid in cooling, Running the intercooler hoses will require some modification but hey i'm game. Thoughts suggestions, welcome. Baz

[SuperchargedSport]

Hi Baz,

The defender and discovery td5 intercoolers are different. one is longer than the other. there are also early and late model td5 intercoolers for each. so 4 in total td5 intercoolers.

The radiator for the td5s has a recess each side too allow the intake/oulet pipes to fit.

You would have to take your radiator/ intercooler out. centre the radiator, have new engine oil cooler lines made, new cooling pipes made, and new intercooler pipes made.

If you say fit an evaporator where the cooler is, the intercooler pipes wont fit around the radiator/evaporator setup as the pipes would need to come through there. An alternative maybe a intercooler from say a toyota soarer or something that is full width but has the inlet/outlet on the same side so you dont have too move the radiator.

An alternative would be to use a td5 radiator which is aluminium which has a better cooling ability than your radiator, but as they dont have an engine oil cooler built in you will have to buy an aftermarket one and make new oil cooler lines.

Iam interested as my brother in law has a 300 tdi defender and we have discussed this many times.... We already have the 02 onwards later model defender nose cone set aside for the conversion. to fit the intercooler in.

[ted44]

hey, I've been pondering this for a while, the best solution for me was being time poor. Was to buy a Allisport intercooler that fits exactly in the place of the 300 tdi defenders intercooler, giving 50% more surface to cool the air into your turbo, expensive in some way I know but less feckin about moving stuff and engineering something that may may not work, if the pipes move further away that may just cause more turbo lag! Allisport do a double core intercooler as well that requires very little redesigning of the radiator enclosure! Are you or have you tweaked the fuel pump yourself? If so how did that go?

[woods130]

I have a tdi300 and noticed oil around the inter cooler hose . what does that mean .

[Jeff]

I have a tdi300 and noticed oil around the inter cooler hose . what does that mean .

Could be oil from the oil cooler fittings being blown there by the fan. Mine did this.

Jeff

[Jode]

I have a tdi300 and noticed oil around the inter cooler hose . what does that mean .

Sorry for the thread hijack:
Do you mean INSIDE the hose or around the OUTSIDE of the hose (say where it fits to the intercooler)? If inside the hose, the turbo typically weaps a bit of oil from the bearing seals under operation, but if you get a LOT of oil you may have a faulty turbo.