Fitting a full size Intercooler to a 200Tdi Land Rover (review)

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After fitting the Land Rover 200Tdi engine as replacement for the 2.5 Diesel Turbo it was getting time to replace the old intercooler unit. Corroded and leaking it was of no use anymore. For replacing it you can use a standard one which does fit straight into the radiator frame or an upgraded one which will improve the power of your vehicle. I opted to try out the full size one (see picture) from Allisport (www.allisport.com)

Removing the old Land Rover intercooler unit:

Removing the old unit is easy, remove the hoses and undo the bolts of the top panel and take off the cover. Remove the plastic fan cowl or loosen it a little bit. It will be easier if you remove it but then you will have to fit it back again. It is also wise to remove the front panel and the top panel with the bonnet lock and the two bars supporting it. I did not remove the bull bar but it will make fitment much easier if you do remove it.

Now you can carefully pull out the old unit (see picture). The radiator on the left has been recored before, you can see it looks like new!

Fitting the new Land Rover Intercooler:

After removing the old unit you can start fitting the new one. The instructions supplied are basic but clear enough. You will have to cut off the bottom edge of the front panel, the little edge which fold inwards to the radiator. These do also hold the two plastic nut for the radiator grille.

The new intercooler has some small brackets which do fit to the chassis supports previously used by the two supporting bars. You can use these and refit the two rubber bushes from the old intercooler. Better is to replace the bushes anyway (part number 572312). The intercooler can now be dropped into it's place.

As you can see it will be a tight fit in front of the radiator and there is not much space left for the front panel and plastic grille.

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