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Intercooler Replacement - DIY

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Old Jul 30, 2024 | 01:55 PM
  #1  
AVLDefender's Avatar
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Mudding
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Default Intercooler Replacement - DIY

Has anyone replaced the intercooler on their own? Curious as to how involved of a job it is. I was told mine needed to be replaced due to a coolant leak. I searched through the forum but could not find anything.
 
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Old Jul 30, 2024 | 02:49 PM
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P400 right? Instructions attached from the JLR workshop manual. I have not done it myself.

PS - You can download P300 and P400 workshop manuals here btw - someone hosts the files.
https://landroverforums.com/forum/20...0-p400-109129/
Make sure you select "view table of contents" when opening in PDF viewer program so you can see the sections.

JLR calls what we'd call an intercooler the "Charge Air Cooler" . It sits right on top of the motor -- should not be that difficult. But draining / vacuum filling coolant is somewhat annoying.

BTW -- So someone told you that the air to coolant intercooler is leaking internally or externally? Just curious. Had not heard of intercooler failures. This might be where all of our mystery missing coolant on the P400's is going if it's an internal leak hahaha.
 
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Old Jul 30, 2024 | 04:54 PM
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Originally Posted by nashvegas
P400 right? Instructions attached from the JLR workshop manual. I have not done it myself.

PS - You can download P300 and P400 workshop manuals here btw - someone hosts the files.
https://landroverforums.com/forum/20...0-p400-109129/
Make sure you select "view table of contents" when opening in PDF viewer program so you can see the sections.

JLR calls what we'd call an intercooler the "Charge Air Cooler" . It sits right on top of the motor -- should not be that difficult. But draining / vacuum filling coolant is somewhat annoying.

BTW -- So someone told you that the air to coolant intercooler is leaking internally or externally? Just curious. Had not heard of intercooler failures. This might be where all of our mystery missing coolant on the P400's is going if it's an internal leak hahaha.
Super helpful! Thank you so much for the info and links.

You are correct P400, I should have specified.

I brought it to the dealer after smelling coolant and finding a low reservoir, with no obvious source of a leak (common story!). They found that the O rings in the turbo were leaking and the coolant was leaking internally on the intercooler.
 
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Old Feb 6, 2026 | 05:28 AM
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I’m actually looking for this PDF. Thank you so much. By the way, speaking of PDFs, I recently came across a pretty interesting free tool https://onlydoc.com/ for working with PDFs and everyday tasks. Considering its user-friendly interface, ease of use, and a solid set of essential features, I think it’s a really good option. I’m sure this tool will come in handy for someone.
 

Last edited by pastlend; Mar 23, 2026 at 08:53 AM.
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Old Feb 6, 2026 | 08:38 AM
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https://drive.google.com/file/d/1DYm...ew?usp=sharing

Download it - -In my Google Drive
(this link won’t be live forever if you find this in the ... future)
 
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