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New Allisport intercooler

pak967

Trekker
Have today finished fitting my nea Allisport intercooler :D :D :D

In the end after much deliberation i went for the direct replacement unit , my reasoning was that im not out for blistering performance, i just wanted a bit more umph to offset the weight if all the off road protection fitted , and a future roll cage.

Also a direct replacement unit is easier to clean , along with the radiator when things have got really muddy .

It was straight forward to fit , just had to remove the slam panel , slack off the hose clips and slide it out .

Hardest bit of the job as it turned out was removing the EGR , both bolts were well seized and rusted on , had to drill and chisel em off.

Fitted the EGR blanking plate and gasket , and removed all the old pipe work, the wiring harness has been left in place along with the control unit attached to the fuel pump , it is integrated into the wiring loom and easier just to leave in place.

Replaced the standard hoses with quite natty yellow silicone ones , and fitted an ITG performance air filter , cat has also been removed for a straight through pipe.

Last job was to turn the fuel pump diaphram 90 degrees and fire her up.

She pushed out some smoke on revs for a few mins then ran clear as day.

Have not taken her out for a full test run today as its windy as hell down here at the moment and will still probably end up going backwards ! :D

Chap at Allisport reckons with all the above mods it should take her from 111bhp to 135-140 bhp , more than enough for my needs .

When it stops blowing a gale outside i wil post the end result of how she performs , well chuffed so far though , great bit of kit from Allisport beautifully made and very helpfull chap .
 

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Not only that...
You'll be able to pull a higher gear than normal.
If you don't push hard your fuel consumption will improve.
Notice also how much more low down torque you have.
 
Not only that...
You'll be able to pull a higher gear than normal.
If you don't push hard your fuel consumption will improve.
Notice also how much more low down torque you have.

Yeah , looking forward to giving it a proper run out , there is a long gradient on a bridge down here i was going to run her up , she is usually out of puff at the top ...but it has today been closed due to the high winds , thats my first test , will see how effective the mods are off road , like you say am hoping for a good improvement in low end torque too
 
Hey pakman, great looking bit of kit that, very sexy!!! Now go out and tell us how she performs!!

AJC also has the direct replacement and when I spoke to him about it he really rated it!
 
Yeah , looking forward to giving it a proper run out , there is a long gradient on a bridge down here i was going to run her up , she is usually out of puff at the top ...but it has today been closed due to the high winds , thats my first test , will see how effective the mods are off road , like you say am hoping for a good improvement in low end torque too

When I got my Defender 110 SW I drove it in town in a 30 limit in top [4th] gear.
Now I've got the Alli-Sport intercooler pump tweak and no center box I can travel at 30mph in 5th gear at 1,100rpm.
 
When I got my Defender 110 SW I drove it in town in a 30 limit in top [4th] gear.
Now I've got the Alli-Sport intercooler pump tweak and no center box I can travel at 30mph in 5th gear at 1,100rpm.

Did you fit the direct replacement or the Full sized one ?
 
I initially set my diaphram to the recommended 90 deg but found there was enormous amounts of black smoke on acceleration which concerned me about the MoT.

Trial and error proved that I still have noticeable increased acceleration with the diaphram set at 35 deg (ish) without all the smoke.

AJ
 
Did you fit the direct replacement or the Full sized one ?

Direct replacement so it wouldn't be noticed :D :D :D

Also I didn't want anything in front of the radiator going into Botswana where grass seeds can get between two radiators and block the water radiator.
 
I initially set my diaphram to the recommended 90 deg but found there was enormous amounts of black smoke on acceleration which concerned me about the MoT.

Trial and error proved that I still have noticeable increased acceleration with the diaphram set at 35 deg (ish) without all the smoke.

AJ

From what i gather its different for every vehicle , though mine seems ok at 90 degrees , i was told it might smoke for a while after the adjustment as the system blows itself clean ...might be worth trying it again at 90 degrees and see how it goes ?
 
Direct replacement so it wouldn't be noticed :D :D :D

Also I didn't want anything in front of the radiator going into Botswana where grass seeds can get between two radiators and block the water radiator.

Is Botswana a suburb of stockton on tees then ? Lol :D
 
i've just fitted a ITG air filter, but to be honest, haven't seen any difference, my new MATE "PORNY" said i'll hear it thru me snorkel..still , early days..what would i get performance wise by fitting a Td5 one...?..sorry i mean fitting a td5 intercooler
 
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i've just fitted a ITG air filter, but to be honest, haven't seen any difference, my new MATE "PORNY" said i'll hear it thru me snorkel..still , early days..what would i get performance wise by fitting a Td5 one...?..sorry i mean fitting a td5 intercooler

Fitting the ITG filter was the first thing i did, you are right on its own there is no noticable difference in power, however i found the truck smoother through the rev band whilst on boost ...in real terms you might get 2-3bhp imrovement from the filter alone , not enough for even an experienced owner to be able to notice .

Where it helps is when done in company with all the other small gains from EGR /CAT removal and new hoses, the Larger gain from the intercooler and fuel pump adjustment ...all added up they make a noticable difference.

Not forgetting a well serviced engine , clean injectors , maybe even some fuel addative such as Millers will add small improvements as well.

I have no idea about fitting a TD5 intercooler, though bigger i would assume they are not alloy , the plumbing will be different , if you have a close fitting winch bumper on a 300tdi you can fit an Allisport TD5 intercooler as it is still full width but not as tall , the return hose is on the opposite side of the cooler so you would have to cut a hole in the inner wing .
 
CHEERS PAK, i'll get me guru PORNY on it, i've already got it tweeked and the EGR thing blanked, supose the intercooler is next then...the exhaust is standard (no cat)but lookin to get a side exit one in the near future...it does pull well and the top end for it (110) is about 85mph, which is good, nice to be able to go on the outside lane on the motorway, if i want..
 
CHEERS PAK, i'll get me guru PORNY on it, i've already got it tweeked and the EGR thing blanked, supose the intercooler is next then...the exhaust is standard (no cat)but lookin to get a side exit one in the near future...it does pull well and the top end for it (110) is about 85mph, which is good, nice to be able to go on the outside lane on the motorway, if i want..

No worries :p ..though i dont know how true it is but i held off on adjusting the fuel pump until i had the intercooler in , as i understood it just increasing the fueling greatly increases the thermal stresses on the head, having the intercooler on compensates for this extra thermal load also .

I stand to be corrected if misinformed :rolleyes: !

...Lol will just need to sort yer brakes out now !
 
Upgrading the intercooler before you tweak anything is obviously the most sensible route to take since there's no possible way you can damage your engine by reducing the induction temperatures - it can only be a positive improvement. Allisport seem to recommend you do this, particularly on the TD5, since if you want it chipping and then you change the intercooler afterwards to get the most out of it it then needs remapping again to account for the increased 'cooler capacity. If you do the 'cooler first you can tweak to your heart's content afterwards.
My 90 has the bigger intercooler but is not chipped, yet it still seems to go slightly better as a result - no doubt more efficient combustion due to extra oxygen in the cylinders. I've also blocked the EGR, and I'm turning in very respectable fuel economy figures from mine when pottering about plus it will really fly when needed.:D
 
I have had my replacement intercooler fitted for six momths now standard size from allisport also done silicon pipes, EGR blanked off unlike yours took it off at the manifold makes a much neater job also took disc shaped sensor off fuel pump, fitted KN filter, replaced cat down pipe with ESR 2740 non cat down pipe plus pump adjustments . Now out accelerates my mates standard td5, also MPG is much better last MOT emmisions were lowest ever and he never said anythiing about not having a cat fitted all in all so much better to drive well worth the time and effort
 
What's the rest of your exhaust system like? I binned the centre 'box in order to make room for an overdrive I'm going to fit, but the Cat front pipe is still in place. I've been advised that the Cat is the most restrictive component of the exhaust. The only thing stopping me binning the Cat is I don't really want to increase the noise levels from the exhaust.
 
Slight increase in noise level after i removed the cat front pipe but only realy noticible when i accelerate firmly . Rest of the system is Rimmer Bros stainless steel been on for about 5 years . But i would say the slight noise increase is a fair trade for the increse in performance and better econemy plus i like the sound of it anyway
 
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