Intercooler

I need a new intercooler for a tdci. It has the same part number as the TD5. I'm looking for a straight replacement and not a performance upgrade. There are a lot of brands available as alternatives to genuine (read grossly overpriced) so I'm looking for advice on which aftermarket ones are ok and which to avoid - based on your experience. Searches have shown the genuine / original ones only last a few years (must be a design weakness). Any thoughts welcome and ta in advance.

Given the short lifespan you mention, I'd consider getting one made - I've used this lot to make various intercoolers:-

www.alutec.co.uk

no affiliation etc.....

Mine lasted 6.5 years but reading on another forum some have failed much earlier. They have an alloy radiator part but the inlet and outlet parts are plastic mouldings clamped onto the ally part. The band which clamps the inlet moulding to the ally core bursts, that has happened on mine and appears to be the common failure. I suspect (read guessing) its down to flexing / movement rather than internal pressure. Opinions welcome.

There are some all alloy ones on the fle bay.

Wimblowdriver said:

Mine lasted 6.5 years but reading on another forum some have failed much earlier. They have an alloy radiator part but the inlet and outlet parts are plastic mouldings clamped onto the ally part. The band which clamps the inlet moulding to the ally core bursts, that has happened on mine and appears to be the common failure. I suspect (read guessing) its down to flexing / movement rather than internal pressure. Opinions welcome.

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I've seen the same failure mode on some modern vehicle water radiators .... A fully welded all alloy one, as mentioned in post #4 would be a good option IMHO - worth a phone call to Alutec - they made me a bespoke oil cooler - 8 times the surface area of the OEM spec for less than £200 - I.E. less than the OEM cost .... - they might even "do" one now - they certainly do other LR stuff, although their main business seem to be diggerers

tottot said:

There are some all alloy ones on the fle bay.

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Not ruling this out. But really want to keep the original volume and it needs to fit in a tight space between the A/C condenser and the cooling radiator so it has to be as slim as the original. The ally ones seem to be larger volume and the extra depth would mask more of the radiator and might affect engine cooling and therefore need a remap due to temp alterations and change in airflow? Really looking for anybodies experience of the Britpart, Allmakes, Bearmach etc copies compared to original. I have found a source of genuine delivery mileage take-offs for sensible money and might go that route.

Why not go for an aftermarket one. Better performance, no negatives and it won't need a remap. But it will run better.