haakon Posted December 14, 2009 Share Posted December 14, 2009 I've got a full size Allisport IC for a 200 tdi which I'm trying to fit into my 300tdi Defender. From what I see they are suppose to be same size and therefore I thought fitting should be straight forward. I'm however experiencing some difficulties First, this is the bottom hose. Can I just cut off a part and fit a silicon hose? Second, I think the IC is sitting a bit to much out towards the bumper. I normally have the front panel sitting behind the receiver here. Should the IC be sitting further back or is moving the front panel the only options? It seems to me that moving the front panel is a bit of hazzle.. The IC is pretty close to the radiator. Brackets are fitted correct? Quote Link to comment Share on other sites More sharing options...
BogMonster Posted December 14, 2009 Share Posted December 14, 2009 Yes to Q1 as it is a pressurised hose so no problem. Not sure about the rest. Quote Link to comment Share on other sites More sharing options...
Aragorn Posted December 14, 2009 Share Posted December 14, 2009 You might have problems getting the pipe to stay on if you cut the barb off the end of it. Might be worth getting some mikalor supra (or similar) hose clamps, as they can apply much more clamping force to the hose unlike the worm drive clips that will start to jump if you go megatight. Quote Link to comment Share on other sites More sharing options...
Bull Bar Cowboy Posted December 14, 2009 Share Posted December 14, 2009 You might have problems getting the pipe to stay on if you cut the barb off the end of it. Might be worth getting some mikalor supra (or similar) hose clamps, as they can apply much more clamping force to the hose unlike the worm drive clips that will start to jump if you go megatight. There is no requirement for the clips to be mega tight as the pressure is only 0.9 bar (12 - 15 psi) so you could probably hold it on securely with duck tape ! ............ just cut the pipe and fit a silicon hose secured with stainless steel jubilee clips.......... Quote Link to comment Share on other sites More sharing options...
The Badger Posted December 14, 2009 Share Posted December 14, 2009 Double check the bonnet latch, as this can catch the top of the intercooler. I had to remove mine and fit something else. Quote Link to comment Share on other sites More sharing options...
Aragorn Posted December 14, 2009 Share Posted December 14, 2009 This months PPC has a car in the "walkers workshop" section that was blowing intercooler pipes off at 1bar of boost, due to having no barbs on the shiney stainless steel hardpipes he'd had fabricated. Few years ago i put a 2.0 engine into my brothers nova, and used a short piece of copper pipe to join two hoses together that were carrying coolant back to the header tank. 10 miles into the test drive after a particularly brisk blast the car started billowing white "smoke". Turned out the hose connected with copper pipe had popped apart, and it was spewing steam out the now disconnected pipe joint. The coolant system runs <1 bar as the blowoff valve in the expansion tank opens at 1bar, yet the standard jubilee clips could not hold the pipe on that copper while under pressure. We ended up buying a proper barbed joiner from the local hydraulic place. You might be lucky and never have an issue, but it can happen! Quote Link to comment Share on other sites More sharing options...
santalars Posted December 14, 2009 Share Posted December 14, 2009 Double check the bonnet latch, as this can catch the top of the intercooler. I had to remove mine and fit something else. ...or just drill a hole in the top of the IC so that the pin can nicely fit in... Quote Link to comment Share on other sites More sharing options...
western Posted December 14, 2009 Share Posted December 14, 2009 I've got a full size Allisport IC for a 200 tdi which I'm trying to fit into my 300tdi Defender I thought the IC pipe locations were different between these 2 models. Quote Link to comment Share on other sites More sharing options...
haakon Posted December 14, 2009 Author Share Posted December 14, 2009 The bottom pipe can be modified or cut. The problem is the depth. It will not fit... This was confirmed by Allisport Quote Link to comment Share on other sites More sharing options...
Lars L Posted December 14, 2009 Share Posted December 14, 2009 And I suppose that moving the radiator back isn't an option on a 300Tdi? That was what I did when converting from 2,5 n/a to 200Tdi. I used the donor Disco's radiator and full width I/C and since the radiator is too high I also moved it backwards. Putting turbo hoses onto straight pipe doesn't work (for long). I know... I have had to flare the alli pipes to get the silicone hoses to stay on. Latest that popped off was after the motorway outside Askim on my way home from Suldal this summer. 120 kph uphill puts some stress on them hoses. And once it slips off, it doesn't stay on if you put it back. Quote Link to comment Share on other sites More sharing options...
ejparrott Posted December 15, 2009 Share Posted December 15, 2009 and used a short piece of copper pipe to join two hoses together that were carrying coolant back to the header tank. I have a trick for doing this....buy yourself a fitting from a plumbing centre..as long as its compression it doesnt matter what it is. You can buy the olives off the shelf seperately. What you do is...take your length of copper pipe, and fit the first end into the compression fitting as if you were doing some plumbing - do it up good and tight. Undo the nut, turn it round, put another olive on the pipe and replace in the fitting, and tighten up again. Loose the nut off again, saw through 2 flats and remove the nut from the pipe and hey presto - a pipe with flared ends! For extra security, a dab of solder can be put on the olives too, but If you do the nuts up good and tight you shouldn't need it, I've never had a problem. The jubilee clip must of course be fitted behind the olive. The oil pipes on my TDi are currently done this way, and have been fine for close to 2 years. That runs up to a maximum of 55psi or 3.74bar. Quote Link to comment Share on other sites More sharing options...
callum Posted December 15, 2009 Share Posted December 15, 2009 just use decent jubilee clips , they'll hold the hoses on. i had trouble with one silicon hose blowing off a straight piece of pipe when i first installed my intercooler. this was the first one out of the turbo which did not have a lip. i had used lubricant to get this particular hose on also, so to solve the problem i degreased both hose and pipe and fitted a higher torque jubilee clip. it has never blown off again and nor have any of the other connections in the system which do not have lips and which are secured with just ordinary jubilee clips. you should be fine, a tdi is not running massive boost pressure. Quote Link to comment Share on other sites More sharing options...
The Badger Posted December 15, 2009 Share Posted December 15, 2009 I fitted a modern 2006 style grill, this means on a 300 tdi you can put the IC in front of the radiator, the grill just goes over it. My Bonnet latch did catch though so I fitted bonnet pins. Quote Link to comment Share on other sites More sharing options...
Turbocharger Posted December 15, 2009 Share Posted December 15, 2009 I'm using plain pipe and had the devil's own job making the pipes stay on, especially at 2bar as I was learning to control the VGT. A bead of weld around any (steel) pipe will work as a flare, but I've opted for three jubilee clips on each one instead, which seems to be holding ok. If you do trim the pipe, stuff some rag in there first to stop yourself filling the i/c with cutting swarf. Ideally, blow compressed air into the other end to dissuade it? Quote Link to comment Share on other sites More sharing options...
white90 Posted December 15, 2009 Share Posted December 15, 2009 http://www.mig-welding.co.uk/forum/showthread.php?t=5553&page=2 Quote Link to comment Share on other sites More sharing options...
haakon Posted December 16, 2009 Author Share Posted December 16, 2009 Anyone got pictures of how the safety bonnet catch has to be modified? I'm getting a 300 tdi IC one of these days, so then I can compare the differences Quote Link to comment Share on other sites More sharing options...
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