NEW LIFT-Pro technology intercooler for Defender TD5, 2.2, 2.4 TDCi

(4 customer reviews)

£398.00 ex. vat

Please email us for availability

SKU: AS112 Category: Fits: Defender 2.2 Tdci, Defender 2.4 Tdci, Defender TD5

Worldwide Delivery

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AlliSport are excited to introduce our latest ultra efficient uprated intercooler for Defender Td5, 2.4 and 2.2 Tdci models; 1999 to end of production.

Featuring our special L.I.F.T (Louvered Internal Fin Technology) hi-flow core design for ultimate reliability and efficiency. 2020-Pro versions further revised and improved!

Lifetime warranty!

Copied, but never bettered

Substantially larger and more efficient than the OEM item which is prone to split.

Uses original pipe connections, only very minor modifications required to install. Suitable for cars fitted with Air Con.

All intercoolers are individually tested to over 20psi before dispatch. This core size is capable of cooling over 600bhp, as proven on our customers World Rally Cross and Gymkhana cars

Independently tested for efficiency and reliability, outperforming standard and competitors products.

Our latest Defender intercooler is the culmination of many years of development, now redesigned upon the introduction of the 2.2 Tdci motor, to cope with the increased stresses caused by modern turbo chargers.

Original design conceived early in 1999 on one of the first cars to be modified (which by the way is still in use with its original intercooler!)
Now completely designed on Solid Works, with Laser cut end tanks and mounting brackets, CNC folded and TIG welded individually by hand in house.

Our design uses high grade 5000 Series sheet metal end tanks, folded from a single piece to eliminate splitting.                                                                                                                                                                  This design is lighter and more efficient than the heavy cast models on the market. Lighter weight means better heat rejection, as there is less material to act as an insulator meaning less heat soak and better recovery times in between boost cycles.

Despite specialising in intercooler manufacture for over 18 years, we have had our design independently tested in the UK against various designs on the market, including cast designs from around the world.
This tightly controlled rigorous independent testing consists of a program of individual tests including heat rejection, efficiency, high pressure test cycles, pressure drop, charge air flow and air flow over the core externally. Results are derived from the average of at least 10 readings per condition.
Each unit undergoes final inspection and pressure test, before being dated ready for dispatch around the world. You will notice all our intercoolers are plain aluminium with no coating. This is because coating acts as an insulator reducing efficiency, plus we pride ourselves in the finish of our products and have no need to cover up any substandard workmanship.
Along with many other products we manufacture, all AlliSport intercoolers are covered by a lifetime warranty – we are so confident this is the best Defender intercooler available today.

We have taken a great deal of time to ensure these intercoolers are easy to fit, a simple replacement for all Defender Td5, 2.4 and 2.2 Tdci models with or without air conditioning. Designed to fit using the original boost hoses. Supplied with fitting guide.

The increased cooling capacity together with the appropriate electronic tuning can allow 2.2 Tdci power output to be increased to over 180bhp with a similar 35% torque increase. Fuel economy improves by, on average 10% with a reduction in cylinder head thermal stress. Thermal stress is actually reduced as the EGT or combustion temperature is reduced dramatically. Power and torque can be increased further with special turbos and improved air flow products.

We also offer in house ECU remapping / rechipping and we stock plug-in tuning modules and performance turbo chargers. Please search the website for more of our top quality products, or send us an email for further information and advice.

Please see some in house manufacturing videos here –

Laser nesting program

Posted by AlliSport on Thursday, 23 February 2017

End tank laser cutting

Posted by AlliSport on Thursday, 23 February 2017

Welding an end tank

Posted by AlliSport on Thursday, 23 February 2017

Additional information

Weight 53 lbs


Model / Series

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4 reviews for NEW LIFT-Pro technology intercooler for Defender TD5, 2.2, 2.4 TDCi

  1. Mr Gordon

    Beautifully made and surprisingly easy to fit even for a novice like myself.

  2. Per-Gunnar Johansson

    This intercooler is a real piece of art and the size is impressive. It covers the entire front of my Defender Td5. Fitting was no problem. Some manual reading and preparations and the intercooler just drop into place. In combination with the silicon turbo hoses the change in driving response was significant. With the snorkel removed the change is remarkable. Acceleration and turbo response up to 120 km/hour is just pure joy and still without tuning. Thanks, Andrew, for your professional advice.

  3. Charlie

    I contacted Andrew asking for an intercooler for my Td5 and received a swift response. He was then able to send out an intercooler, with next day delivery, before the end of the same week. I have just fitted it to my vehicle and I’m sure that the engine picks up better than it did beforehand. Since I already run my Td5 with a remap, I now know I have that extra security of the larger intercooler and the ability for some more power in the future. A definite must for anyone looking to improve the Defender!

  4. Lieven / LRC-Motors

    Top quality products and perfect service!
    Can’t go for a better option then the Allisport products, only the best is good enough!
    Keep up the good work.

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AlliSport strive to produce the highest quality products designed to withstand many years of use and we are proud to stand behind these products. However, we manufacture many products and if you make enough of anything, a limited number of problems may be expected. It is how we deal with a problem that is important!

Effective January 2016 onwards, if your product fails due to a manufacturing defect we will repair or replace it without charge, at our discretion. Only original, unaltered and unmodified materials and workmanship are covered by this policy.

This warranty does not cover damage caused by accident, improper care, negligence, normal wear and tear, or the natural breakdown of materials over extended time and use.

Damage not covered under warranty may be repaired for a reasonable rate and a fee will be charged for return shipping.

The products eligible for warranty are covered to the original owner, for the lifetime of the product.  Unfortunately, this does not mean your lifetime. Your AlliSport® intercooler may not survive to the ripe old age of 70.

(But we have heard from happy customers whose well-loved and cared for 1999 products are still going strong!)

For warranty evaluation, your product must be returned directly to AlliSport Ltd, Aubrey’s Farm, Bromesberrow Estate, Ledbury, Herefordshire, HR8 1RZ, UK.

All shipping for warranty must be pre-paid and insured and accompanied by reference to the original invoice. We cannot be liable for lost or damaged in-bound packages.

Not all AlliSport products are covered by the lifetime warranty, please check the warranty tab on the product detail page for further info.