AS112 – Defender TD5 & Tdci Uprated intercooler – NON AC
1. Remove grill, engine cover & fan cowl
Find a prop for the bonnet as you will be removing the bonnet stay
2. Slacken the top 4 bolts and remove lower 2 bolts to remove the alloy panel
3. Remove the bottom stay bar bolts
4. Remove the top slam panel bolts
Note: Later models have studs that will require a lock nut threaded on to remove from the wing. Carefully allow the slam panel to hang on the bonnet release cable
5.
6. Remove inner wing brackets
2 x 8mm head bolts
7.
8.
9. Remove intercooler top bolts and hoses
10. Lift out the intercooler right hand side first
11. 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!
12a. Remove the two plastic mouldings from the radiator (1)
12b. Remove the two plastic mouldings from the radiator (2)
13. Slot the new intercooler into position on the radiator - Right hand side first.
You can now refit – Hoses, top intercooler bolts, Inner wing side brackets (leave finger tight to allow Alignment later) – refit bonnet catch slam Panel and bottom stay mounts Use 35mm m8 bolts and 10mm Spacers supplied with kit
14. Check security catch clears the intercooler.
Carefully close bonnet checking security catch alignment. Adjust security catch to miss the intercooler if necessary. Check bonnet pin with latch alignment, it may be necessary to lengthen the pin.
15. It may be necessary to lengthen this bonnet catch rod
16. With bonnet closed, tighten Bottom stay bar bolts fully. Open bonnet and tighten 8mm Inner wing bracket bolts
17. New bolts and spacers supplied
18. Final checks
– Refit alloy grill surround panel and tighten the 4 slam panel to wing bolts.
– Refit engine cover, fan shroud and grill
– You can now check everything is nice and tight, making sure the car is ready for a test drive.