200 TDI intercooler upgrade

Lej · Dec 22, 2019

Hi there,

As the title suggests, I am looking to upgrade the intercooler on my 200 TDI. I have just fitted a boost pin and quickly realised I'm not running at capacity because my old intercooler is more of a wind shield than anything of purpose.

I'm looking to upgrade to a double depth 116mm instead of the 65mm standard and I was just wondering what modifications would be required to allow for the increased size?

Many thanks

Pappasmurf · Dec 23, 2019

Slightly shorter hoses maybe.

lynall · Dec 23, 2019

Think you will find they are drop in jobs, maybe as Pappa suggests a little off the hoses but that will be evident when you fit it, which will be a piece of ****.

Ian Maycock · Dec 23, 2019

https://rover.ebay.com/rover/0/0/0?mpre=https://www.ebay.co.uk/ulk/itm/133029784287 If it’s like the one in the link then you may have too , I fitted one to my 90 300tdi project and I had to modify the frame to get it to fit how I wanted it too as they stick out both sides can put a pic up tomorrow if you want ? Or if you look in the members vehicle section Ian’s 90 300tdi rebuild I think there’s some pics in there .

v8250 · Dec 24, 2019

Lej, you do have another option and that's to fit a higher quality intercooler with greater efficiency core which will provide same size footprint as the std intercooler. I looked into i/c's for a good while, weighing up options and decided to invest in the AlliSport Std size unit which gives 20+% increase in power and, most importantly, torque. Mine's installing onto a brand new engine which is a clean 125bhp prior to the i/c upgrade...once mildly tuned, I'll be very happy with 140-150bhp.

https://www.allisport.com/shop/perf...coolers/allisport-200tdi-uprated-intercooler/

Ian Maycock · Dec 24, 2019

If you want to spend that sort of money you can go for a front mounted full width Ali sport one , I’ve got one fitted to my 110 200tdi , I did some testing with thermocouples on the inlet and outlet temps the drop in temp was quite large .

lynall · Dec 24, 2019

v8250 said:
Lej, you do have another option and that's to fit a higher quality intercooler with greater efficiency core which will provide same size footprint as the std intercooler. I looked into i/c's for a good while, weighing up options and decided to invest in the AlliSport Std size unit which gives 20+% increase in power and, most importantly, torque. Mine's installing onto a brand new engine which is a clean 125bhp prior to the i/c upgrade...once mildly tuned, I'll be very happy with 140-150bhp.

https://www.allisport.com/shop/perf...coolers/allisport-200tdi-uprated-intercooler/

Dont forget no matter how efficient any intercooler is, it alone will not produce any extra bhp over a std unit.

neilly · Dec 24, 2019

Ian Maycock said:
If you want to spend that sort of money you can go for a front mounted full width Ali sport one , I’ve got one fitted to my 110 200tdi , I did some testing with thermocouples on the inlet and outlet temps the drop in temp was quite large .

How did it comparetemp wise with the thermocouples for the std and uprated new size intercooler?

CHeers

windy81 · Dec 24, 2019

just go full size and be done with it, lower your egt's at the same time as increasing available power

Ian Maycock · Dec 24, 2019

Unfortunately I can’t say for the standard intercooler as I fitted the full width one when I rebuilt the truck and ended up measuring the temperatures in a discussion on another forum , if you fancy a read here’s a link .
https://forums.lr4x4.com/topic/104474-intercoolers-and-other-bits/#comments

Lej · Dec 26, 2019

Thanks for the response everyone,

I have been toying with the idea of getting a front mounted intercooler with a full frame sized radiator at the back of it like the TD5's have. The problem is that I can't find a kit that has both the intercooler and radiator supplied and would I need a frame for it? I'm worried that if I purchase a radiator and an intercooler online that they won't match up...

Alternatively could I just buy a TD5 set and modify the hoses? I have a short bellhousing on my defender which means the 200 tdi engine sits quite far back to the bulkhead and I have installed electric fans, doing away with the viscous.

For instance, what brackets (if it's doable) would I need to fit this kit?

https://www.ebay.co.uk/itm/INTERCOO...fender&hash=item5d96d9be6a:g:9TMAAOSwPhdU9IJr

Many thanks for the response everyone, love the support these forums have!

dag019 · Dec 27, 2019

Lej said:
Thanks for the response everyone,

I have been toying with the idea of getting a front mounted intercooler with a full frame sized radiator at the back of it like the TD5's have. The problem is that I can't find a kit that has both the intercooler and radiator supplied and would I need a frame for it? I'm worried that if I purchase a radiator and an intercooler online that they won't match up...

Alternatively could I just buy a TD5 set and modify the hoses? I have a short bellhousing on my defender which means the 200 tdi engine sits quite far back to the bulkhead and I have installed electric fans, doing away with the viscous.

For instance, what brackets (if it's doable) would I need to fit this kit?

https://www.ebay.co.uk/itm/INTERCOOLER-RADIATOR-KIT-FOR-LAND-ROVER-DEFENDER-2-5-TD5-1998/401962810986?fits=Modelefender&hash=item5d96d9be6a:g:9TMAAOSwPhdU9IJr

Many thanks for the response everyone, love the support these forums have!

You do not need that. the standard radiator is more than adequate for a tdi, and if anything the engine is already over cooled. You simply fit a full sized inter-cooler in from of the radiator. You remove the two stiffening rods behind the grill, use their attachment points for the inter-cooler brackets and the inter-cooler then acts as the stiffening rods. similar to the below (google pic):

I would also echo the above sentiments about an inter-cooler on its own making no difference to the power output of the engine. The larger inter-cooler allows you to increase the fueling to up the power without raising the egt and causing damage to the engine.

Lej · Dec 27, 2019

Hi Dag,

Thanks for replying!

I would be happy with that but would I have to shunt the radiator over to the center to allow for the pipes? Or are both input and output on the same side of the intercooler?

I have installed a boost pin, boost ring and tweaked the fuel pump which is why I'm looking to better the cooling.

Would you be able to point me in the direction of an intercooler that would do the job?

Many thanks!

lynall · Dec 28, 2019

Lej said:
Hi Dag,

Thanks for replying!

I would be happy with that but would I have to shunt the radiator over to the center to allow for the pipes? Or are both input and output on the same side of the intercooler?

I have installed a boost pin, boost ring and tweaked the fuel pump which is why I'm looking to better the cooling.

Would you be able to point me in the direction of an intercooler that would do the job?

Many thanks!

Tape measure ebay and search for universal intercooler, there are endless optons.

200 TDI intercooler upgrade

Lej

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Pappasmurf

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lynall

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Ian Maycock

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v8250

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Ian Maycock

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lynall

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neilly

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windy81

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Ian Maycock

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Lej

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dag019

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Lej

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lynall

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