Vehicle & Technical > Discovery

TD5 Intercooler into 200 tdi upgrade, i've made a start.....

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ne jones:
:D  After placing a wanted add for a Td5 intercooler I got to buy one from Hightower which was delivered yesterday.

This afternoon I got to take a look at what was actually involved in fitting it into the front of the 200 tdi Discovery.

After removing the grill and headlight surrounds I offered the 'new' ic to the front of the car and from this was able to determine how best to proceed with the fitting, it was obvious it wasn't going to be as straight forward as  first thought.

The front panel to which the bonnet closes is supported by 2 braces going from the bonnet catch diagonally to the bottom of the small panel where the horns are fitted. I unbolted both of these bars and removed them.

Next after offering up the ic again I decided that the right hand horn had to be removed completely as did most of the metal the horn bolts to. Out came the grinder, I think picture 0209 shows what I used it for  :D

The right side had to be cut away as 0211 pictures to clear the inlet on the ic.



On the left hand side the horn was reversed and only a small amount of trimming was required.

There is now sufficient room for the 'new' ic and when the standard ic is removed i'll be routing the pipework through the vacated area.

Now a plea for help as i dont own a welder and need some brackets fabricating. Is there anyone reasonably close to me that would be prepared to help me with this part of the upgrade please?

Gotta get me some silicone hoses now and sone straight pipe so that the plumbing can start.

If you can help us out then please let me know.

Dr Neil:
keep the pictures coming Nathan,i've got my intercooler now but haven't got time to start on it yet.I've got access to a welder but i'm a bit far away.
Good look mate

Neil....

ne jones:
Neil it all happened rather quickly.

Went to my brother in laws to weld up the brackets to moount the i.c and to have a mooch at the pieces of stainless tube he had in his garage.

Firstly I got the 2 90 degree silicone elbows and put them on the new i.c and offered it up infront of the radiator. To keep the ic as far back as possible i cut approx 1.5 inches off each elbow @ the ic joint. I also took the same amount off the other end of the elbow for the inlet side.

On the front chassis legs right where the bumper mounts to the chassis we measured and made some 80mm longx10.5mm internal diameter tubing for locating the 2 lugs on the td5 i.c.

I had bought some 90 degree steel brackets for 60p each and these were cut down and welded to the underside of the front panel where the bonnet catch is, the ic bolts to these brackets.

The front locating lugs on the ic were cut off too.

We removed existing i.c and cut down its plastic cover to give access into the engine bay down the side of the rad.

A piece of stainless comes from the outlet side of the ic diagonally across the front of the radiator and bends into the engine bay and uses the stock top ic hose.

The inlet side uses the stock pipework from the turbo going into a u bend then into the silicone elbow on the ic.

Finally the front grill required very minor trimming of its inside to all ow it to fit.

I'll take some pics of the job and post them later today.

All in it took us about 3.5 hours + the cutting I did in the previous installment.

ne jones:
Some pics

1st one inlet from Turbo

2nd one is outlet to inlet manifold

3rd one is obvious.

ne jones:
3 more

1st one shows original pipework from turbo

2nd one shows original pipework joined not to original intercooler but to the bend which goes to the silicone tube on the ic inlet

3rd one shows use of original hose to the inlet manifold, the ic outlet is connected to this pipe by a stainless pipe with bend around rad and silicone elbow on the ic.

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