AS112 – Defender TD5 & Tdci Uprated intercooler – AC
1. Open the bonnet
You will need to prop open the bonnet
2. Remove plastic fan cover
3. Remove the large screws each side
4. Remove the 4 screws along the top
5. Remove the AC extension
6. Remove 10mm bolt
7. Remove 2 13mm nuts
8. Remove studs
Use 2 nuts locked together to remove studs threaded into the inner wing
9. This is one of the studs removed
10. Lift out the bonnet slam panel
11. Remove the left hand wing bracket
12. Remove the right hand bracket
13. Remove intercooler hoses
Use a flexi hose driver to remove the intercooler hoses
14. Remove both top intercooler securing bolts
15. Lift out the intercooler right hand side first
16. Cut wing bracket
The right hand wing bracket will need cutting as shown here. Make sure that you touch up the bare metal with some paint!
17. Remove two plastic mouldings
Before fitting the new intercooler, two plastic mouldings need removing – on one each side.
18. This is the left hand plastic moulding that needs removing
19. Carefully lower the new intercooler into place left-hand side first
20. Insured that the radiator is located on the chassis mounts before proceeding
Note: this one is NOT seated correctly
21. This side is ok
22. Don't forget these spacers if fitted
23. Reverse the removal procedure
You can now reverse the removal procedure, securing intercooler, hoses, wing brackets and AC mounts. Once this is complete, you can refit the bonnet slam panel.
The end result
Hopefully your car will look something like this!
When you are satisfied everything is tightened up and secure, you can carefully make sure the bonnet closes securely.
Take the vehicle for a test drive before undertaking a long journey!