Shall i fit a new intercooler?

[Benji]

Having a bit of a problem with power.....or lack of it when towing (which is all the time) so been thinking about fitting a new and improved intercooler as they quote up to 30% more power.

Has anybody fitted one and can you recommend a manufacturer and supplier?

Are there any drawbacks, like long term engine damage?

Thanks guys.

Ben

[robbie]

interesting question, I dont know the answer but am interested too

[muddyweb]

Uprated intercoolers will help, and will provide more torque / power.  As to the 30%, I wouldn't like to say.

In any event, they need to be fitted as part of an overall upgrade... the engine and fuelling will need to be adjusted at the same time, else you won't get the benefits and that's where damage can occur.

I wholeheartedly recommend Allisport for this... His prices include fitting at their workshops in Gloucester, he knows what he is doing and is generally a nice chap.

[Budgie]

If I was to do it again I think I'd go with Allisport as well.
I've got an Allards kit fitted in the Disco and it works well but I could never get hold of anyone while I was fitting the kit and the parts turned up, in dribs & drabs, over about a week or so.

When it came to doing the fueling I took advice from Allards but also used this site http://dodgeram.org/tech/dsl/more_power/Power_ve.htm which explains the process well. I would take note of the warnings though and if your not sure what your doing, don't try.
Some of the adjustments on the site can make a difference without a larger intercooler, although it will have greater affect with one.

If you make any alterations to the injector pump settings then make sure you make a note of what you've done so you can put it back if it doesn't work!!!

[Disco Inferno]

Mine was done by jeremy fearn as fitted upgrade,
This in cluded an dintercooler the size of devon, boost increase, and pump modification.
Goes like brown smelly stuff off a shovel

[philbert]

Fitted an allisport intercooler and adjusted the pump and boost on my 200 tdi.totally different beast now will tow anything with ease and thats with higher gearing.

[Budgie]

Three things I forgot to add:

I've not played with the turbo boost yet, mine is still as it left the factory.

Try removing the intercooler and cleaning it, inside & out. It will make a difference if it's not been done for a while.

With the clean intercooler refitted (make sure it's dry inside!) have a look at the URL I posted above for instruction and try turning the diapham 90 degrees clockwise.
There should be a centre punch mark on the metal centre of the diaphram, take a note of it's position so you can move it back if necessary, mine was at 12 o'clock as you look at it from the drivers side wing but I've heard this isn't always the case.
What your doing with this alteration is increasing the amount of fuel available to the engine, as standard the are set to the minimum, and without a larger intercooler to supply more air, if you go over the 90 degrees then you could just be blowing unburnt fuel out of the exhaust.  

You may find this will give you extra power your looking for and all it's cost is your time!!  :D
It's an easy job and takes about two minutes to do and to put back if you don't like it.  

[scorpio]

Having a bit of a problem with power.....or lack of it when towing (which is all the time) so been thinking about fitting a new and improved intercooler as they quote up to 30% more power.

Has anybody fitted one and can you recommend a manufacturer and supplier?

Are there any drawbacks, like long term engine damage?

Thanks guys.

Ben

I had exactly the same problem I thought it was due to the larger tyres I had fitted and would have to live with it. I took the EGR valve off last week and fitted sillicone turbo hoses what a difference that made it now tows up hills at 60 it may be worth you trying this option first as it is a lot less money and even if it doesnt help will still be needed to do the intercooler mod later.

[simondarby]

Yep,

Another satisfied Allisport customer here!

Full width beast fitted last year and I'm still smiling ear to ear!

Damn nice chaps too.

Still playing with fuel pump.  Not overly confident mechanic so I am taking it carefully...

Overall, plenty more power than before.  Even managed to embarass my good friend who has just bought a 2001 TD5 Disco!! (what a shame...)

Si

[Benji]

Well thats cheered me up no end!

My local specialist wants £520 inc for an Allard intercooler (fitted) but it sounds fairly easy to change them over. He said that it shouldn't need any adjustment to the fuel system but it sounds like it might be a waste of time unless other parts are adjusted.

I can't imagine that the standard intercooler has ever been cleaned so i might try that and taking the EGR off as well. Although the MOT is booked for Monday so id better wait until after then!  :)

Ill give allisport a call tommorrow to get a price from them.

Thanks for the advice, anymore views still appreciated.

Ben

[muddyweb]

Allisport will be cheaper than that... fitted...  I guarantee it ;-)

And they will adjust your fuel system accdordingly,  not to do so is pretty pointless.