BigJock2005
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Just wanted to post and confirm that you 100% absolutely can remove the intercooler on a TD5 Defender with aircon without removing the radiator.
It's not difficult, but there are two pitfalls: the slam bar is held in with studs into a captive bolt with a bolt on the other side. You need to remove the stud to get the slam bar out, and simply unbolting won't work, you need to double-nut it and remove the whole stud; second the two couple of jubilee clips on the intercooler hoses face the inner wing and are a total b'tard to loosen.
Took me about 2 hours (because I'm not very good) but 45 minutes of that was getting the jubilee clips loosened. You really need Harry Houdini hands plus a 6mm combi to get to them turned. Patience and beer gets them loose eventually.
But essentially, just take off the grille, take off the slam bar, remove the bonnet stanchion plate on offside wing and same on nearside, both with wiggle out and the rubber mount will easily come out of the intercooler.
Once you've got the air pipes off the intercooler, the rad will lean back just enough for you to carefully lift out the intercooler.
If anyone needs any pics let me know.
Very good link below which I used, thanks to "ChrisA":
http://www.bluelion.org.uk/landrover/2014/05/01/td5_intercooler_installation.html
I just posted this, because I found conflicting information on the web, but above is first hand.
It's not difficult, but there are two pitfalls: the slam bar is held in with studs into a captive bolt with a bolt on the other side. You need to remove the stud to get the slam bar out, and simply unbolting won't work, you need to double-nut it and remove the whole stud; second the two couple of jubilee clips on the intercooler hoses face the inner wing and are a total b'tard to loosen.
Took me about 2 hours (because I'm not very good) but 45 minutes of that was getting the jubilee clips loosened. You really need Harry Houdini hands plus a 6mm combi to get to them turned. Patience and beer gets them loose eventually.
But essentially, just take off the grille, take off the slam bar, remove the bonnet stanchion plate on offside wing and same on nearside, both with wiggle out and the rubber mount will easily come out of the intercooler.
Once you've got the air pipes off the intercooler, the rad will lean back just enough for you to carefully lift out the intercooler.
If anyone needs any pics let me know.
Very good link below which I used, thanks to "ChrisA":
http://www.bluelion.org.uk/landrover/2014/05/01/td5_intercooler_installation.html
I just posted this, because I found conflicting information on the web, but above is first hand.
