Removing TD5 intercooler

lightning · Oct 20, 2015

I want to take off the intercooler to see if it's got oil in it. I looked online and this job appeared easy enough.

However l got stuck trying to remove the metal strip that goes across the top and holds the bonnet catch.

It is held on by two nuts at each end, and the bolts appear to be captive. As in they don't move when you take off the nuts.
So the metal piece won't come off as the bolts/studs (which won't move) prevent it being lifted out?

What's the answer? l put my hand inside the wing and could feel the threaded studs held by what felt like a captive nut.

ProcrastinatorFraser · Oct 20, 2015

Personally i thought there were more than just 2, weren't there?

lightning · Oct 20, 2015

There's a black metal strip that goes between the tops of the wings at the front with the bonnet catch in the middle of it.
It has two nuts at each end, then there's a larger metal plate to remove on each side which will release the intercooler.

But after removing the nuts, the bolts/studs won't move so the metal strip won't come off.
So you can't remove the metal plates which have the intercooler top brackets on them.

gazman · Oct 20, 2015

I took my rad out to get mine out as its a huge aftermarket thingy and is attached to the rad.

Great excuse to change the engine coolant

lightning · Oct 20, 2015

So can anybody tell me how to get the standard unit out?
It's supposed to be possible without removing the rad or viscous fan.

jamesmartin · Oct 20, 2015

this might help, though personally id only remove one if necessary
https://www.google.co.uk/url?sa=t&r...HiCTDyNU-X-UlV5TQ&sig2=pDR4Gk4qPLDBF1hP6mNWgA

bankz5152 · Oct 20, 2015

Mine was pretty easy. Got to pull the whole front grill off.

The only captive nuts i came across where holding the intercooler to ther rad, i can to basically cut the intercooler off.

lightning · Oct 21, 2015

jamesmartin said:
this might help, though personally id only remove one if necessary
https://www.google.co.uk/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&cad=rja&uact=8&ved=0CCAQFjAAahUKEwiChIn2ktLIAhWKthQKHVOoBkE&url=http://www.alivetuning.com/wp-content/uploads/2014/02/Defender-Td5-Intercooler.pdf&usg=AFQjCNG6IN96-ZqTwHiCTDyNU-X-UlV5TQ&sig2=pDR4Gk4qPLDBF1hP6mNWgA

Thanks for that, looks like you need to put two nuts on each stud and withdraw them that way.

MrNasty · Oct 26, 2015

I used a stud extractor to remove the 4 studs, then when I was putting it back together I simply used bolts and chucked the stupid studs, why the retards at Land Rover did not use bolts I don't understand.

lightning · Oct 27, 2015

Yes it does seem a bit strange to put studs into the captive nuts with another nut, rather than just use bolts as on the sides of the front grille just below!

Removing TD5 intercooler

lightning

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ProcrastinatorFraser

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lightning

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gazman

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lightning

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jamesmartin

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bankz5152

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lightning

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MrNasty

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lightning

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