I bet this is gonna cost !!!!

Over the last 2 days whilst under load I could hear a hissing, air leak type of noise with black smoke evident out of exhaust under load

(black smoke is excess fuel due to loss of air due to leak)

Found the intercooler had decided to split on one of the air chambers

Strangely though I dont feel any loss of performance

Ah well sort out customers cars tomorrow first then its workshop doors shut, dial a pizza, Red Bull and the heater on and lets start stripping - lol

Range Rovers - You just got to love em !!!

May even try to tig weld it !!

oooohhh la la

mine started hissing before too, but it just blew off one of the intercooler hoses

Use some Epoxy on it
I had trouble with the inter-cooler rad rubbing against the main radiator and causing leaks especially after the corrugations in Mongolia and i fixed it with epoxy resin and its lasted for 10 000 miles so far

2.0_hippo said:

oooohhh la la

Click to expand...

Dont you start

RS2000CUSTOM said:

Dont you start

Click to expand...

op2:

Hhhhmmmmm maybe a bigger intercooler is in order - Under Hippo here we come !

ovalandrover said:

Use some Epoxy on it

Click to expand...

will be trying this stuff as well after carefuly crimping the gap shut !

At least I can get a pattern part for £150ish !!

Intercooler - PML000011 | Range Rover L322, Range Rover 2010 > | Range Rover | British Parts UK

RS2000CUSTOM said:

Hhhhmmmmm maybe a bigger intercooler is in order - Under Hippo here we come !

Click to expand...

RS2000CUSTOM said:

will be trying this stuff as well after carefuly crimping the gap shut !

Click to expand...

Open the gap up force it in then crimp the gap shut and let it set

Do it properly and change it !

ovalandrover said:

Open the gap up force it in then crimp the gap shut and let it set

Click to expand...

There's the chance of some going into the intercooler, setting as little crumbs and then being sucked into the engine.

Well I managed a temporary repair using Aluminium repair epoxy (similar to quick steel)

Sadly not 100% gas tight but a major improvement

Good old Thiefbay came to the rescue though - a brand new genuine intercooler for £90 !!!! (pattern part £150+ vat genuine £340+ vat)

Gen BMW 7 Series 730d (E65, E66) Range Rover III 3.0 Intercooler 2001 - | eBay