Member Since: 22 Jun 2011
Location: West Midlands
Posts: 1218
Intercooler replacement
Good afternoon, today we have replaced my leaking intercooler, so as you will see from the pictures front of the car stripped down, remove coolant I then removed oil cooler lifted up out the way condensor radiator , removed removed viscus fan intercooler pipes and top radiator pipes, remove radiator securing bolts lift radiator and move forward to remove and fit new intercooler and then put it all back together in reverse ,fill up with coolant bleed system and run on test , cleared faults took down the motorway no more restricted performance, job took me and my friend six hours with a few tea breaks,
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20th Oct 2024 12:53 pm
faulksy
Member Since: 24 Dec 2023
Location: powys
Posts: 344
nice work had a d1 ,d2 a land mark d4 for 3 days now have awsome d4 in orkney grey hse sdv6 my12
Member Since: 25 Nov 2019
Location: Shropshire
Posts: 44
Boost leak leading to limp mode.2015 SDV6 Commercial
27th Oct 2024 7:55 pm
M3DPO
Member Since: 22 Sep 2010
Location: Notts.
Posts: 8244
Never realised the intercooler was so big, looks like your friend is geared up for the job complete with spare straight six engine and washing machine , well done both of you It can when others can't,
It will when others won't,
It goes where others don't.
28th Oct 2024 8:05 am
Sundayjumper
Member Since: 23 Sep 2024
Location: Berkshire
Posts: 110
How did you determine it was the intercooler at fault ? Smoke test ?
I'm getting an occasional restricted performance and a fault code for air flow correlation, but it must be quite a small leak as it'll drive fine normally, and cruise on the motorway at 70-80 no problem, but reliably happens on a local long uphill drag at 40-50 where I guess it's asking for sustained boost. Assuming it's a leak not a dodgy sensor, it could be anywhere and I don't know where to start. No other fault codes.
28th Oct 2024 10:22 am
stephenw46
Member Since: 22 Jun 2011
Location: West Midlands
Posts: 1218
I was towing caravan up a long climb in Luxembourg and went into restricted performance mode, I pulled in services read fault codes boost pressure and mass airflow codes when I got home you could see oil in intercooler area leaking smoke test confirmed hope this helps
28th Oct 2024 12:28 pm
stephenw46
Member Since: 22 Jun 2011
Location: West Midlands
Posts: 1218
As for my friend being geared up that M57 engine is being rebuilt to replace the V8 rover in his defender here’s a few photos of his L32 thousands spent on it
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28th Oct 2024 12:32 pm
Sundayjumper
Member Since: 23 Sep 2024
Location: Berkshire
Posts: 110
stephenw46 wrote:
I was towing caravan up a long climb in Luxembourg and went into restricted performance mode, I pulled in services read fault codes boost pressure and mass airflow codes when I got home you could see oil in intercooler area leaking smoke test confirmed hope this helps
Thanks. That does sound similar. I'll have to get out there with a torch and start looking for clues.
28th Oct 2024 1:09 pm
M3DPO
Member Since: 22 Sep 2010
Location: Notts.
Posts: 8244
Washing up liquid is your friend to find leaks It can when others can't,
It will when others won't,
It goes where others don't.
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, well done both of you 
