ALLISPORT INTERCOOLER

by COLIN BATCHELOR

Now that Andy Ryder and myself are booked in to compete in the Macmillan 4x4 Challenge, I decided that it would be a good idea to upgrade the intercooler to make the car more responsive and easier to drive.  On my recent drive through Norway and into Sweden, I found the car to be very sluggish, especially uphill, so whilst I was at the Peterborough show I had a chat with the guys from Allisport, and duly arranged a fitting date.

I arrived at the Allisport workshop at around 10.30am and was introduced to Ian Day the technician who would be fitting the intercooler in my 1995 300TDI Discovery.

Ian first connected a boost gauge to check that all was well with the turbo and took the car for a spin.

The next step was to remove all of the indicators, front grill etc to gain access to the position where the intercooler would be fitted. 

Whilst this was carried out, Andy Graham, the owner of the company, began welding my intercooler together.

The radiator was removed to allow easy access to the holes that would have been used by Land Rover for the fitting of aircon.  The antifreeze was kept and reused, as it was quite new. 

At this point Ian also removed the EGR, as it would not be needed, as the intercooler would be more efficient without it.  I also had a new non-cat down pipe fitted at the same time thus enhancing the flow of exhaust gasses as well.

A blanking plate (genuine Land Rover part) was fitted to cover the hole left behind when the EGR was removed.

What all of this adds up to is that the coolest air possible enters the turbocharger, which gives you more horsepower and also reduces the engines thermal stresses.

The fuel compensator was also altered to allow for the different characteristics of the power delivery and a new pro-filter air filter was fitted.

By now the new intercooler was ready.  It sits in front of the radiator and apart from using the pre existing holes; Ian also fitted two extra brackets, which will hold the intercooler firmly in place.

I purchased the optional blue coloured silicon hoses, only because they looked better than the standard ones that I originally had, but they are said to be a lot stronger than the factory fitted items.  Stainless steel jubilee clips were used throughout.

Once everything was bolted, screwed, filled up and checked over it was time for another road test.  Ian came back and pronounced the job a success.

To say that I am impressed would be a major understatement.  I must admit to being sceptical when I read various articles on the various intercooler companies, but I can now accelerate uphill, where before I would have had to change down a gear and still have lost speed.

Driving is now a much more relaxed affair, as there is a lot less stirring of the gearbox to keep up with the traffic.  Also fuel consumption has improved slightly.  Andy tells me that the car will perform even better after a couple of weeks as the engine cleans itself out of all the old sooty deposits.

The quality of the workmanship is second to none, and Andy’s welding is nothing short of a work of art.  Both Ian and Andy were only too pleased to answer any questions that I put to them and they took time to explain exactly what they were doing and why (they also kept me supplied with loads of coffee)

Allisport also carry out one off fabrication work, including making long-range fuel tanks etc. If your insurance company require a written statement of the work carried out and the effects on the vehicles performance Allisport will be happy to provide one.

Total time for the installation was around 3hrs, but this did include them repairing one of my anti roll bar mountings (thanks guys)

For more information contact ALLISPORT

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