Intercooler removal 200tdi Defender

Not a big job really, manual says about removing the fan, cowl, etc. Ah didn't have the right tool for removing the fan, so here's how ah did it....

First ah removed the two nuts holding the cowl on ( be carefull 'cos the stud can break very easily like one of mine did!!!)......




then removed the 4 bolts on top of the panel (2 each side)....



and then the other 4 bolts (2 each side) on the slam panel..



Removed the panel to see the top of the intercooler (and radiator)...



Next ah removed the top pipe and then the bottom pipe from the intercooler....





Then to give me a bit of room to move the cowl about, ah removed the top radiator hose, lost a wee bit coolant but nothin' major, then unclipped and moved the air filter up out of the way...



Then with a bit of jiggery-pokery the intercooler came out from the top....



to clean it, all ah did was stick some thinners in it and gave it a good shaking about to remove any oily crud, then did it again until it was clear. Left it outside in the air last night and all day today to get rid of the fumes and let it dry out.
Refitting is pretty much the reverse. Just remember to top up the coolant and the job's a guid one

This is just a couple of pics of the bus with "it's" intercooler removed, and the clean one going in.....

Treworgey 90 said:

I have "modified" my fan cowl by cutting some strategic bits out of it. It can now be removed easily, without removing the top hose or the fan (not that I've got the fan fitted anyway).

Click to expand...

Good tip that Trewy, must remember that for the next time

Just make sure that whatever ye use to clean out the intercooler has dried out completely before puttin' it back in. Also while yer at it, it might be an idea to clean and check the hoses comin' from the I.C to the turbo for splits i.e the rubber elbows.