If you are thinking about fitting an aftermarket or performance intercooler to a Td5 Defender fitted with factory aircon have a quick read of this - it might save you a few problems in the future.

I fitted a performance intercooler and some 20 miles later realised I had fouled a radiator hose in the belt that drives the aircon. On the right of the engine bay the belt passes very close to the radiator hose as standard - ensure that after fitting the intercooler that you have not reduced this clearance or lost it altogether. Performance intercoolers don't seem to be made to the same level of precision as the factory item and therefore there is a chance that others may encounter the same problem. The radiator on the Td5 is partly aligned by the intercooler and the intercooler, built to a diffeent tollerence, pushed the radiator sligtly further into the engine bay - along with the coolant hose.

If by chance you do end up with the belt cutting into the radiator hose you can look forward to around £30 to replace the hose but more frustrating is the lack of space to get access to the lower connections of the hose and the time taken to replace it.

Incidentally fitting an intercooler to a vehicle with aircon is not as straight forward as a Td5 without aircon. The main problem being the lack of access and the tight space to work in. Allow a good few hours for fitting.