Allisport Intercooler 300Tdi w/ A/C Question

I'm looking to swap in an Allisport intercooler into my 300Tdi powered 110 that has A/C installed. It looks like Allisport makes 3 different sizes.
Uprated
Double Core
Full Sized

I know that in the AZ summertime (50 degrees) the full sized unit may create an engine cooling issue with it restricting the airflow thru the radiator so I'm looking at the uprated and double core. The A/C condenser interfering with the double core unit is the cause of my concern. What are your experiences and solutions for going double core? Pictures are always a great help if you did some kind of modification.

I had a previous Disco 300 tdi with AC and a full front intercooler. It never gave any cooling issues and that was in summer stop start traffic in 30+ degree heat, off roading and towing. I don't agree with the school of thought to removing the viscous fan, a brand new or fully working viscous unit does not give any measurable gains in mpg or power when removed (a seized one will do though!) so always leave mine fitted.

The key to is to make sure the radiator is in good nick and the fins are free of mud etc, the same goes for the ac condenser.
Make sure the viscous unit and fan work correctly, the coolant is to spec, the water pump is to spec and the thermostat is working correctly. The 300 is a fairly cool running engine anyway. And don't forget, a larger intercooler with the correct pump settings will actually LOWER charge temps/combustion temps a little. If you are still experiencing cooling issues, maybe look to create a way to let hot air escape behind the engine, ie a small vent in the wing or bonnet, or add an electric fan in front of the IC. but I don't think you will need it.

Javelinadave said:

I'm looking to swap in an Allisport intercooler into my 300Tdi powered 110 that has A/C installed. It looks like Allisport makes 3 different sizes.
Uprated
Double Core
Full Sized

I know that in the AZ summertime (50 degrees) the full sized unit may create an engine cooling issue with it restricting the airflow thru the radiator so I'm looking at the uprated and double core. The A/C condenser interfering with the double core unit is the cause of my concern. What are your experiences and solutions for going double core? Pictures are always a great help if you did some kind of modification.

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Question. As you are in the USA, where fuel, especially petrol (aka gas) is pretty darn cheap. Why are you running a Tdi?A Rover V8 will p1ss all over a Tdi in terms of performance. And not really be that much worse on fuel. Not to mention easy access to many other alternative V8's that you could also run.

BTW - I'm a two Tdi owner, so far from against the Tdi.

As for the intercooler. Don't go into it thinking it'll transform the vehicle. They won't. Not if you've already tweaked the injector pump. What they will do is allow the same level of tuning with less smoke and lower EGT's or maybe slightly more peppy. But it really won't be a massive leap in performance.

Although going from untweaked to tweaked Tdi will give a massive seat of the pants increase.

I have a full width Allisport Intercooler that was fitted by Allisport on my 200Tdi and tuned by them at the same time. It goes well, but even in the UK it is quite possible to raise the engine temp on long drags on slight inclines. I don't have AC either.

My Uncle has a full width Jermey J Fearn intercooler on his 300Tdi that was also tuned by them. One of the best Tdi's I've driven and has done around 140,000 miles in tuned state. But it too will make the temp gauge go up, especially when towing on hills. No AC either.