Disco 1 Allisport intercooler and oil cooler

New intercooler to improve performance and bigger auto box oil cooler to resolve overheating issues just arrived. I will post intercooler photos as I have not seen any on here for the larger direct replacement unit from allisport for the Auto 300tdi. Should keep me busy on weekend.

KNine said:

I will post intercooler photos as I have not seen any on here for the larger direct replacement unit from allisport for the Auto 300tdi.

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My mate has fitted an Allisport intercooler to his 300Tdi automatic last year along with a few other improvements, variable vane turbo included, I have to say I do not think the money was well spent, performance wise alongside my stock old Disco Tdi manual there appears not a lot of real performance improvement, and we have done some side by side comparison runs, I know how much all these "improvements" have cost, and apart from being able to maintain higher speed on highway hills I can't see the value.
After all it is a 4X4 that is super capable in "as built" trim, not a sports car, but the accessory salesmen are happy I guess.

I hear what you are saying Gazbo, there always seems to be contradicting reports on the value of fitting an updated intercooler. One thing that can't be denied is that it will lower EGTs. I manly use my car for overlanding and have been to Morocco twice. My main problems have been gear box oil overheating and poor performance on the long steep hills. I am hoping that these new parts will help overcome these shortfalls.

Looking forward to hearing how it goes with the bigger Intercooler. You would normally adjust the fueling, do you have a manual pump or EDC?

Hi,
I have fitted the bigger Allipsort intercooler and a Ronbox on my 300tdi Auto EDC. The Ronbox was already installed and makes an improvement especially in lower gears. I was full of hope for the intercooler but to be honest I did not notice any major improvement. Next step would be to increase the boost on the turbo or head to a VGT but I'd love to here from anyone who has had good results before spending any more on this.

Hi, I got Andy to fit the whole monty, cooler, rad turbo, tuning box. As well as all new silicon hoses on my 98 disco 300tdi auto.
One thing I will say is it isn't a drag car, and after getting it home I had a few more bits of things to do to get it right and notice a definate difference, first changed all the injectors. Had a new genuine lift pump fitted. Had the fuel pump fully serviced, stripped and cleaned the auto box professionally, renewed injector pipes. New quality piper air filter,Spent a day fine tuning the box. Smoke no smoke etc.
When I'd done all the work I took it off road to try on hills and mud upto axles etc performed spot on definate improvement. Next took it down a road by flooring it. Went great until in top at around 3000 rpm was stalling and begging for fuel. changed the Maf sensor and set it up again.
Goes like stink, but bear in mind it's still a bloody heavy 4x4 and on the road will get its arse kick by lighter models.
Regarding the cost about 4/5 grand was it worth it, to me yes love it and enjoy the reaction when somebody gets in with a normal one. If you don't have a fortune to spend do the basics, it's a great truck to mess around with, don't buy the turner staged head made no difference at all, just give your a good de coke next time heads off,
Hope this helps
Grex

Hi Grex - which tuning box did you fit ?

The one that Andy supplies. It's been the only one tried and tested by him on vehicles he's fitted, there's plenty of adjustments in it, if I remember right just keep turning right for more power and/ or until it smokes then back of qtr of a turn. I even at one time converted the pump back to mechanical and tried it that way but reverted back. I'm not in any way saying the tun box is the way to go I feel there's more gains to be had with the mech, but I liked the overall extra Bhp and control over the range with the EDC, but that's to everyone's personal choice.
I must admit a big difference was replacing the old tired injectors. Expensive but with new heater plugs started and run a lot better.
The only thing I did was update the brakes, the disco needed some better stopping power, not just for the extra bit of speed but with the extra full weight of accessories.

Oh I'm getting an extra 8ish miles to gallon also and absolutely no smoke at anytime. I've checked mixtures to make sure she's not to lean or rich. The maf sensor is free of soot and oil just a lovely grey colour. Air filter is checked regularly as running with snorkel. Which doesn't make life easy

Fitted the duel core intercooler today, just a case of grinding off the return folds on the radiator near side frame. Also trimmed 10mm off the fan shroud where it meets the intercooler. I was intending to fit a mechanical injector pump and tune, but have decided against that and intend to get the EDC pump tuned.

Seems to be accepted wisdom that the EDC has a better delivery curve than the VE pump and can make more power.

Gazbo said:

My mate has fitted an Allisport intercooler to his 300Tdi automatic last year along with a few other improvements, variable vane turbo included, I have to say I do not think the money was well spent, performance wise alongside my stock old Disco Tdi manual there appears not a lot of real performance improvement, and we have done some side by side comparison runs, I know how much all these "improvements" have cost, and apart from being able to maintain higher speed on highway hills I can't see the value.
After all it is a 4X4 that is super capable in "as built" trim, not a sports car, but the accessory salesmen are happy I guess.

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You're not comparing apples to apples though, the auto will still have been blowing a load of power off into the torque convertor.
I think a lot of folk do run into issues of "butt dyno" innaccuracy though. For example comparing a plugged up, orrible intercooler to a new shiny one (the stock one would have been as good...)

theflyingvegetable said:

Seems to be accepted wisdom that the EDC has a better delivery curve than the VE pump and can make more power.

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My plan is to stick with the EDC pump so that it can constantly monitor and deliver the correct mixture regardless of country / climate, so morocco or Iceland. The EDC calibration / tune will take into concideration the extra cooler air from the larger intercooler, delivering more fuel, but keeping the EGT,s as normall. The extra power will be great on long hills in hotter climates and help with overtaking on my local B roads. I hope to get the pump sorted next Friday if I can get it booked in.
Fitted the EGT sensor today so have included a few pics. The sensor fits into a bung cut to 45 degrees so that it enters into the manifold, as oppose to sitting in the cup where the EGR used to be.

Auto box oil cooler now fitted so a few photos.

KNine said:

Auto box oil cooler now fitted so a few photos.

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How you going to keep that from getting packed with mud

Mud? Don't go near the stuff with that shiny bit of kit, or cover it with a bin bag

Thor1950 said:

How you going to keep that from getting packed with mud

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Put the grill back on