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Old 11 Sep 2008
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Larger Intercooler for TDi

does anyone has any opinion about useing a larger intercooler in LR with 300 TDi engine?

Many thanks in advance.

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Old 11 Sep 2008
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What are you trying to achieve? More power, more torque, better fuel economy?
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Old 11 Sep 2008
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I have a Allisport intercooler in my 300TDI 110. On the pros, it is really good in terms of noticeable mid range power. Given my 110 is kitted up for overlanding with roll cage, roof rack, winch, etc, its carrying a fair amount of weight, sits significantly higher than a standard 110 and the intercooler has really helped giving more usable power. On the cons, my engine always used to stick ridgedly to the same temperature where as these days it does run a bit hotter when working hard such as at motorway speeds. Its only appeared since the intercooler went in (about 4 years ago) but it has developed over time so I can't directly attribute it. It could be partially down to the aging vehicle, its now about 13 - 14 years old.

As to fuel economy, it will partially come down to the way you drive. Personally I tend to use the extra performance. In theory, the intercooler should allow you to achieve what you currently achieve with less effort from the engine and therefore you economy could improve. Depends on whether you use the extra power.

If you do decide to do it, I found Allisport to be excellent, very professional, easy to do business with and 4+ years on and had no problems.
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Old 12 Sep 2008
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Thank you Toby2 for info. I wonder what kind is better, a large intercooler installed in the front of rad or standard size one but more efficient. I've seen Allisport ones - quite nice.
How about necessary settings on pump? How about extra stress on other parts of engine ?

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Old 12 Sep 2008
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Smile 300 tdi intercooler

Hi there. I used one from allards, in my disco 300, 1996. As with Toby, i struggled to see the temp gauge move before it was fitted. The cooler sits in front of the rad, and hence takes a little cooling air from it. In fact now, i am happy to see the gauge move a bit. The engine appears a little better for it. Easy fit, if doing it yourself, and comes with the silicon hoses that you need. I moved the steering resevoir a little, just to be happy in my own mind, that nothing would rub.
Performance wise, i noticed a small improvement in the midrange, but it appeared to move the power band down the rev range. Before, the disco would cope with most things, somewhere around the 1800/2500 revs. Now it will happily cope with the same type of driving with the revs sitting at 1400/2000. This suits my style of driving, so therefore am very pleased with the results.
Both allard and allisport are in the same neck of the woods.
Fuel economy has stayed the same at 27.5 mpg.
Hope this helps,
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Old 12 Sep 2008
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Allisport everytime, i had one of Andys' intercoolers on my 90 (300Tdi) and will get one on my Td5 110 when i've finished building it.

although i'm slightly biased, as i know him quite well and work on some of the vehicles he has down there sometimes.

Still top quality kit though.
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Old 13 Sep 2008
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I bought one from Matt Savage, and combined with the tweaks to the fuelling and boost compensator diaphram on the injection pump it made a big difference to a very heavily laden 300Tdi Defender. Fuel pump tweaks here:
300Tdi tuning
They are also somewhere on the 'net with pictures, but deleted that bookmark when I bought a Toyo...
IMHO the intercooler really needs to be done alongside a bit more fuel, otherwise all you are doing is dropping your intake charge temperatures a little bit (and getting a tiny bit more power which you might struggle to even notice on a heavily laden 4x4). When I installed the IC and test drove immediately before adjusting the pump I would have to say I didn't notice a real difference, but the two together - definately!
I didn't do it, but I know that a few people chasing more power also plumb the hose to the waste gate actuator from the inlet manifold, thereby ensuring the turbo compensates for the larger volume of the bigger intercooler. I was definately looking for more power with my 300Tdi before I sold it, and was also considering a home made water spray system and maybe a pusher electric fan in front of the IC. The last two modifications in theory would have been to compensate for the fact that a front mounted air to air IC will not be that efficient in slow speed off road work, and as well as the fact that a front mounted pusher fan might help with engine water temp. When I turbocharged my troopy I fitted (at the same time) a pyrometer or exhaust gas temperature gauge as I really didn't want engine damage as a result of subjecting the engine to excessive stress. If I had kept the Defender then a EGT gauge would also have been a priority, especially as I know to my cost (albeit from coolant loss) that the 300tdi can be quite a sensitive engine :-( My goal was always increased power but not decreased reliability, so for that reason EGT gauge and boost gauge are quite important, especially if like me you have no access to rolling roads to measure power during/after set up.
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Old 15 Sep 2008
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I run a full-width Allisport intercooler on my 200tdi, fitted by Matt Savage. Very pleased with it, fully laden I regularly get over 30mpg or up to 85mph.

I was worried about airflow being restricted (intercooler, also spots and winch solenoid in front of radiator now) and had a Pacet fan fitted (and viscous fan removed), which is brilliant - engine is very well cooled now (though Pacet often not needed anyway)

Id highly recommend the full-width intercooler.
'91 LR 110 Def/Disco hybrid "Elsa"
Bring me the horizon....
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