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Intercoolers


BogMonster
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Looking particularly at Allisport ones.... much better value for money than any others I have looked at before.

Has anybody driven both the Option 1 and Option 2 intercoolers for 300Tdi engines in similar vehicles4, and what did you think of the difference back to back?

I'm thinking about one or other but the Option 1 is much easier due to hydraulic piping for the winch, being a straight drop-in replacement for the old 'cooler, but I was wondering if I would be disappointed and wish I had gone for the option 2. I've already tweaked the pump so it goes a lot better than it should anyway :)

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A little detached, maybe, as I've never bought or used an uprated intercooled LR; although my 110 should be receiving one sometime this year, but here's my 2p worth anyway.

I've spoken to both Alisport and Brunel (and Mr Fearn) and various specialists on this matter.

There seems to be some concern over the full-width intercoolers and their ability to:

a. allow proper cooling of the engine

b. be properly cleaned after off-roading.

One case involved a guy with a 300Tdi who had a full-width unit and took his 90 off-road regularly. He experienced cooling problems and, after discussion with a respected LR specialist, replaced the full-width unit for a standard size free-flow unit.

Apparently, he reported no discernible loss of performance, but his cooling was much improved and he could actually clean both rad and intercooler properly.

Brunel quote a good 20bhp increase for their standard-size unit and an additional 5-10bhp over that for the full-width.

Price-wise, Brunel's price for the standard free-flow unit is cheaper than Alisport's. I was quoted £275 all-in for Brunel and £285 + VAT by Alisport. Both included free fitting and pump mods.

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i was thinking of going the std size route as my winch sits back a fair bit so there limited room.

Brunel seem to get good reports as do alisport.

what if you just fitted the intercooler and didnt touch the fueling would you get an increase in nm etc as the air must be cooler.

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i was thinking of going the std size route as my winch sits back a fair bit so there limited room.

Brunel seem to get good reports as do alisport.

what if you just fitted the intercooler and didnt touch the fueling would you get an increase in nm etc as the air must be cooler.

tbh when i fitted my full width intercooler untill i tweaked the fueling all i noticed was a very slight increase in speed uphill. as a diesel's power output is limited by fueling i wouldnt expect any real gains till you adjust the fueling to take advantage of the extra oxygen the engine gets supplied with. 110bhp's worth of diesel is 110bhp's worth no matter how much air its got with it.

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i was thinking of going the std size route as my winch sits back a fair bit so there limited room.

Brunel seem to get good reports as do alisport.

what if you just fitted the intercooler and didnt touch the fueling would you get an increase in nm etc as the air must be cooler.

James, you'll notice very little in the real world - I replaced the intercooler for a standard sized Allisport job a couple of years ago. My thoughts were along the same lines as yours. Also, EGT is much more of a problem with long periods of wide throttle opening at high rpm - not something that happens very often off road. Get yourself an EGT gauge and you'll be fine.

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for there to be any effect if you changed the intercooler wouldnt you at least need to change the boost pressure from the turbo as the air flow rate will be different?

So would just fitting a larger intercooler possibly limit performance as even though the air is cooler and denser it wont be flowing at the desired pressure.

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I've had both option 1 and 2 on my 200tdi. I found the option 2 tended to block the flow of air to the radiator causing the water temp to rise to alarming levels (particularly on long runs and in the summer). I changed to an option 1 when went to a d44 recessed winch bumper setup. Fits neatly in where the original sat and no restricting of the airflow. Haven't measured the egt change between 2 and 1, but having the option 1 has got to keep the level more in check than a standard intercooler.

The power gains you get with these things are of course more to do with the pump tweaks and boost level adjust than the actual intercooler itself. I thought on a 300tdi you were supposed to leave the boost as standard (1 bar??)

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The reason I wonder about going for the "easy option" is because while the benefits of one three times the size are obvious, I honestly can't see how twiddling with the shape of the fins leads to a 40% increase in cooling, or whatever it is that most of them claim (about that, I think) as I would have thought the restriction was on the cooling airflow through the intercooler, it isn't a very big frontal area.

At present I have slightly tweaked fuelling and the std intercooler and with the EGT gauge I find that the EGT rises quicker but the all time max is still only about 640, and a "thrash it and see" session before I touched anything got the max up to 618 so it hasn't made much difference to the temps, only to the driveability!

However I may now be going to get a new vehicle so it might be on hold :)

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