Looking at Intercooler Options (nothing too crazy)

So was told by a mate other day that my Intercooler is looking a bit worse for wear, (it definitely looks a bit shabby and tired)

I was thinking of replacing it or upgrading it, but tbh I don't know what to go for. The prices seem to vary wildly from about £100 for something like this

Intercooler Core - Land Rover Discovery / Defender 300TDI 2.5TD 94-06 | Gravity Performance)

To higher end stuff from the likes of Ali Sport 300 Tdi uprated intercooler - AlliSport

I know full width ones exist, but tbh I can't deal with the hassle of having to modify stuff to get it to fit and for what I do in my 90 CSW I don't think it would really be needed.

The basic £100 I'm sure would be better than the one its currently got on it, but just wondered if anyone knew what would be best option

One thing I have noticed it seems to be quite difficult to find an exact replacement for mine, so wondering if they have perhaps been phased out for much more modern stuff?

Forgot to mention mine is a 1999 300 TDI 90 CSW

Hi, I was in the same position as you a couple of years ago and looked into this as the one in my 200tdi was much like yours.
Unless you have a tuned up 300 or tend to work it hard then stay with standard intercooler, it will be better than your old tat one for sure.
Most coolers available now are aftermarket and wont look quite the same.

tottot said:

Hi, I was in the same position as you a couple of years ago and looked into this as the one in my 200tdi was much like yours.
Unless you have a tuned up 300 or tend to work it hard then stay with standard intercooler, it will be better than your old tat one for sure.
Most coolers available now are aftermarket and wont look quite the same.

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Thanks I think I might go for Gravity one then?

Regarding install does the radiator have to come out as well? The limited videos I have seen they all seem to take the radiator out too, but to me it looks like it would just slide out without needing to do that?

A standard replacement should show improvement over what you have. It will be clean inside and out, no missing or bent fins etc
While you're at it, clean any oil out of the pipes, check for any cracks starting

The 100 quid one looks like an easy drop in bargain.
All 300 are the same, 200 have slightly different hose positions but can be made to fit.

ryan_1993 said:

Thanks I think I might go for Gravity one then?

Regarding install does the radiator have to come out as well? The limited videos I have seen they all seem to take the radiator out too, but to me it looks like it would just slide out without needing to do that?

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Took the lot out on mine as needed to renew the rubbers under the rad/cooler frame so cant say. Good time to drain refresh coolant.

ryan_1993 said:

Thanks I think I might go for Gravity one then?

Regarding install does the radiator have to come out as well? The limited videos I have seen they all seem to take the radiator out too, but to me it looks like it would just slide out without needing to do that?

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Yes they fit by just taking the top rad section off, there iof ocurse will be other piffly stuff in the way like maybe fan and shroud if still fitted.

Much easier if you take the rad out completely .... not to difficult.
You can then clean up the slam panel, get new rubbers and fit the sealing foam between the intercooler and radiator ...

tottot said:

Unless you have a tuned up 300 or tend to work it hard then stay with standard intercooler,

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+1 - Though I have a full width on my 300Tdi.. AND it was worth the effort, ( 146 Hp and quite a lot of torque.. ), it was a faff..

tottot said:

it will be better than your old tat one for sure.

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+1 again

Wasn't there a 'thing' years ago, where everyone had to 'upgrade' with a water mister to 'boost ' the cooling efficiency? Or did i dream that

kermit_rr said:

Wasn't there a 'thing' years ago, where everyone had to 'upgrade' with a water mister to 'boost ' the cooling efficiency? Or did i dream that

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Water injection was/is a well known "thing" on large diesels.. I'd say pretty much unnecessary now.. but hey..

https://www.dieselworldmag.com/diesel-technology/wild-water-injection/

Disco1BFG said:

Water injection was/is a well known "thing" on large diesels.. I'd say pretty much unnecessary now.. but hey..

https://www.dieselworldmag.com/diesel-technology/wild-water-injection/

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I meant spraying water over the intercooler to evaporate heat buildup

kermit_rr said:

I meant spraying water over the intercooler to evaporate heat buildup

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Ah, ok, but that happens all the time high in the Pennines ... s'all natural init

kermit_rr said:

I meant spraying water over the intercooler to evaporate heat buildup

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I ain’t got a scooby, but

Def90man said:

I ain’t got a scooby, but


View attachment 281804

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My evo h@s @n intercooler w@ter spr@y.

So I bought the cheaper Gravity performance one which looks quite decent for money.

does any know though if I have to remove the front plastic LR grille to get the radiator frame out? Apparently there is some bolts,

Reason i ask is I have a nudge bar with wired up spotlights on the front and I would really l like to avoid having to disassemble my bumper and my front end if it can be done without doing all that would save time

Taking the front bumper off is relatively easy.
This allows you access to get the front grill and panel off.
This lets you get the slam panel support brackets off and get access to the colts undernbeath the slam panel that hold the bonnet catch/cable assembly off.
at this point the slam paneol unbolts and lifts off exposing the radiator and intercooler.

The front panel 'hooks' on apart from 1 M8 bolt, I slotted mine so it's easier to get out at a later date.

ryan_1993 said:

So I bought the cheaper Gravity performance one which looks quite decent for money.

does any know though if I have to remove the front plastic LR grille to get the radiator frame out? Apparently there is some bolts,

Reason i ask is I have a nudge bar with wired up spotlights on the front and I would really l like to avoid having to disassemble my bumper and my front end if it can be done without doing all that would save time

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You should be able to remove the grill and slam panel without removing the lights and nudge bar. I have a full bullbar and spots on mine and can get it off without removing them. I managed to remove quite a lot of my front end for the rebuild before I gave in and removed the bumper.