Upgraded intercooler systems and Samco Sport silicon hose kits for TD5, 2.4 Puma, TDV6, and TDV8 Land Rovers.
An intercooler upgrade is one of the most effective supporting modifications for any turbocharged Land Rover diesel — particularly when combined with an ECU remap or injection pump calibration. The intercooler's job is to cool the compressed air from the turbocharger before it enters the engine. Cooler, denser air means more oxygen per combustion cycle, which translates directly to more power and cooler EGTs (exhaust gas temperatures). For a Defender or Discovery working hard in Australian heat, the original intercooler's capacity is often a limiting factor.
The original rubber intercooler hoses on Land Rovers are a common failure point. They harden, crack at the joins, and collapse under high boost — particularly on remapped engines where boost pressure exceeds factory levels. Samco Sport silicone hose kits are our preferred replacement. Samco kits are manufactured to OEM dimensions but use high-quality silicone construction that handles higher temperatures and pressures indefinitely. We stock Samco kits for:
For customers who have already remapped their Land Rover and want further performance gains, a hybrid turbocharger is the next step. A hybrid unit uses the standard turbine housing but fits a larger compressor wheel, increasing airflow capacity significantly. On a Defender TD5, a hybrid turbo fitted alongside an ECU remap and silicone hose kit can push output beyond 160 kW. We supply and fit hybrid turbo kits that are matched to our ECU maps for optimal results.
Where direct airflow allows, we can fit larger-core intercoolers with improved heat rejection. These are particularly relevant on vehicles used in sustained high-load conditions — towing in summer heat, or extended outback driving at highway speed.
Our workshop is at 18/62 Argyle St, South Windsor NSW. All intercooler and hose work is performed by Land Rover specialists with over 30 years of experience. Call (02) 9679 1978 or email info@davisperformance.com.
Upgraded intercooler and Samco hose kit for Defender and Discovery 2 TD5.
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Learn moreSamco hose kits for Discovery 3/4 TDV6 and Range Rover Sport TDV8.
Learn moreThe intercooler cools compressed air from the turbocharger before it enters the engine. Cooler air is denser — it contains more oxygen per litre — so the engine can burn more fuel and produce more power for the same boost pressure. A larger or more efficient intercooler also reduces intake temperatures, which lowers exhaust gas temperatures (EGTs) under load. This is important for reliability on sustained highway or outback driving.
We strongly recommend replacing rubber hoses with Samco silicone hose kits when remapping. The higher boost pressure from a remap increases stress on original hoses, and cracked or collapsing hoses are a common cause of power loss and boost leak faults after a remap. Samco kits are a modest cost relative to the remap price and eliminate a common failure point.
Yes. We stock Samco Sport silicone hose kits for the Discovery 3 and 4 TDV6 (2.7L), as well as for the Range Rover Sport TDV6 and TDV8. The TDV6 has several induction hoses that benefit from upgrading — particularly the large corrugated air intake hose which can crack at the clamp points on high-mileage engines.
A hybrid turbocharger uses the standard turbine housing (so exhaust manifold fitment is unchanged) but fits a larger-diameter compressor wheel. This allows more airflow at higher boost pressure. On a Defender TD5, a hybrid turbo fitted alongside an ECU remap can push output to 160+ kW. The key is matching the turbo specification to the ECU map — we supply and calibrate both together to ensure the combination is reliable and produces power across a usable rev range.
Samco silicone hose kits are effectively lifetime components for normal-use Land Rovers. Unlike rubber hoses, silicone does not harden or crack with heat cycles. Once fitted, they should not need replacement unless physically damaged. This makes them good value compared to periodically replacing failed rubber hoses.
Samco hose kits are sold as direct replacements for OEM dimensions, so basic mechanical knowledge and correct clamp torque is sufficient for installation. However, for vehicles that are also being remapped or having other performance work done, combining the hose replacement with the remap appointment makes sense — the boost system is pressure-tested as part of our post-remap process, which confirms all hose connections are sealed correctly.
Indirectly, yes. Cooler intake temperatures mean the ECU can deliver more efficient combustion without the protective richening it applies when intake temperatures rise. On a remapped vehicle, an improved intercooler can help maintain the efficiency gains from the remap under hot conditions. For non-remapped vehicles, the gains are less significant — the ECU doesn't use the additional cooling headroom the same way.
Our South Windsor workshop is ready to help. Contact us today and we'll get back to you promptly.