The intercooler on my 2002 TD6 has sprung a leak!

Three effects:

1. Small quantities of oil ejected under pressure and hitting the cooling fan. Result is that a tiny film of mucky oil coats everything in sight and drips onto the driveway.

2. Intermittently, engine power drops dramatically for a few seconds, picking up again once I can persuade the engine revs to rise. Not much fun really.

3. Very occasionally, a high pitched whistling sound.

I have just had a quote from a very good local independent LR specialist to replace the intercooler as follows:

- Part: £402
- Labour: £294

But a look on ebay tells me I can get a new intercooler from the OEM for £177 delivered. http://www.ebay.co.uk/itm/RANGE-ROVER-L322...3a8259e6b8

Thy say they won't fit a part I source myself.

My question is: does anyone have any experience of what is involved in replacing the intercooler? It's pretty well buried and I can imagine having to take apart most of the front end of the vehicle - but the labour price quoted makes me think they believe its a max of 4 hours work. Make that 6 for me with less experience and I think I'd give it a go.

I've had a look at my copy of RAVE but it does cover the TD6 engine. There is a PDF of part of RAVE available online that does cover the TD6, but this only has the System Description and Operation manual, not the other document that gives details of what is involved in carrying out specific service and maintenance functions.

Any experience you can share really appreciated.

Thanks

Steve Current: 2010 Range Rover L322
Vogue SE, TDV8 3.6, Bournville
-----------------------------------
Now gone: 2002 Range Rover L322
Vogue, TD6, Giverney Green

Just one more thought - bit of a long-shot, but perhaps worth a try.

I gather that the 04/10 and 05/10 copies of the magazine Land Rover Enthusiast had a pair of articles on removing and replacing the intercooler on this vehicle. I don't suppose anyone has either of these two knocking around?

I'd be happy to buy them from you, or really grateful if you could scan the relevant articles?

There is a copy of the 05/10 one on ebay at the moment, but that seems to deal with re-installing the new intercooler. I can't believe that would be so difficult if I'd already managed to remove the old one! What I really need is the 04/10 one.

many thanks

Steve Current: 2010 Range Rover L322
Vogue SE, TDV8 3.6, Bournville
-----------------------------------
Now gone: 2002 Range Rover L322
Vogue, TD6, Giverney Green

Before you buy one, have a look at ours -

http://www.advancedfactors.co.uk/8ml376723...1581-p.asp

OEM Behr unit for £123.96 plus delivery Paul Redding
+44 (0)23 8052 2760
paul@advancedfactors.co.uk

Excellent, thanks Steve - cheapest price I've seen - just working out how to remove the old one! Current: 2010 Range Rover L322
Vogue SE, TDV8 3.6, Bournville
-----------------------------------
Now gone: 2002 Range Rover L322
Vogue, TD6, Giverney Green

Only seen the D3 IC come off - Grille, Headlamps, Bumper then all fairly obvious Paul Redding
+44 (0)23 8052 2760
paul@advancedfactors.co.uk

Enough of the front end to release two plastic clips (I've taken bumper off, but not really convinced I needed to, except to clean up some of the oil). Then IC comes out through the back, which means removing viscous fan to make enough space. Now to try to remove the viscous fan! Current: 2010 Range Rover L322
Vogue SE, TDV8 3.6, Bournville
-----------------------------------
Now gone: 2002 Range Rover L322
Vogue, TD6, Giverney Green

Could you not ask the independent specialist to source the part from AF on your behalf rather than original LR part?

Or is there some other reason they don't want to fit a non LR original IC.

If they have no good reason as to why they will not fit the OEM part then maybe you should take the car to another independent that will.

Personally I have never come across this situation and have always had my car maintained by independents. The only exception to this would be if the parts you wanted to supply were clearly inferior parts or the independent felt the parts would not fit correctly etc.

@steveball.

Cleaning out my inter-cooler is one of the items on my "to do" list. It keeps getting put to the bottom of the list as having looked at it closely the inter-cooler does indeed seem buried.
I don't suppose it would be possible for you to take a few photos and a short step by step of the access and removal procedure? I have a suspicion quite a few on here would be interested and very apreciative of your efforts.

All the info I can find is NAS, so doesn't have the Td6 in it.

I have got a UK RAVE on my hard drive at home, I'll take a look for you in a bit

Right, have fired up the steam powered old Rave, here you go:

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Thanks so much Martin that's really fantastic. Any ideas where I can lay my hands on the version of RAVE that you have for future reference?

As folks removing the intercooler is quite involved and is far from quick. For those like me that have no option but to replace it, that's just one of those things. I can't see that it's worth it, however, for the fun of cleaning out a perfectly healthy intercooler.

Steve Current: 2010 Range Rover L322
Vogue SE, TDV8 3.6, Bournville
-----------------------------------
Now gone: 2002 Range Rover L322
Vogue, TD6, Giverney Green

Thanks Martin that is exactly what I needed. No excuse now.
With regard to removing and cleaning out intercoolers the purpose of doing so is to maintain cooling efficiency thereby maximising mass air flow to the engine.
Over the years the inside surfaces become progressively covered in an oil based dirt which reduces heat transfer. Cleaning them out using petrol or other solvent based liquids results in maximum cooling performance being re-established.
Having cleaned a few out in the past it 's amazing how much dirt collects in them.
Unfortunately the TD6 intercooler seems to require a not inconsiderable amount of work to remove it, obviously this is a consideration when deciding whether the benefits of cleaning are sufficient to warrant the work involved.
Steve... I would be interested to know the mileage of you car and how much dirt is in you intercooler when you finally remove it if possible. Thanks

If you want the Rave with TD6 info:

http://www.fullfatrr.com/forum/post177952.html#177952 .
Experience is the only genuine knowledge, but as time passes, I have forgotten more than I can remember
Volvo V70 P2 2006 2.4 Petrol 170bhp Estate SE
MG Midget Mk1 1962

Previous: L322 Range Rover TDV8 3.6 2008; L322 Range Rover TD6 3.0 2002; P38A Range Rover V8 1999

I've done it
Have a look here
http://www.fullfatrr.com/forum/topic10807.html
And
http://www.aulro.com/afvb/l322-range-rover...ooler.html

You need a day to give yourself time to do the job properly first time round.
Best of luck.

Adrian VW Amarok 2014 Highline auto