Leaking intercooler

MooLard · 08-02-2018, 03:15 PM

Hi there
Next fault after several others appears to be the intercooler. I have been trying to trace an oil leak by cleaning the underside of the engine and tray and this evening checking again for fresh oil.
I have replaced the boost pipe seals and it’s a bit clearer now, it seems to be coming from the intercooler core to plastic end cap join on the exit side, has anyone seen this or had this happen to them before? The car doesn’t feel slower as in loosing boost, bit harder to tell on warmer days. Can I be mistaking this for a leak somewhere else?

Recent repairs include transmission oil pipe replacement, valve cover gasket replacement, small turbo solenoid, map sensor, and boost pipe to intercooler seals. All over the course of eight weeks too...
Thanks in advance,

Owen81 · 08-02-2018, 08:24 PM

There are seals on the exit side as well, did you do those?
I had oil seeping out from the silcone hose to hard pipe section on that side of the engine as well. This would be easy to see as there will be a stream of residue originating from that connection, down to the intercooler connection.

MooLard · 08-02-2018, 10:46 PM

H thanks for the reply, yes I’ve replaced the seals on the exit of the intercooler side: the aluminium pipe that goes up to the inlet manifold.
The leak looks to be coming from where the fan shroud meets the inside of the intercooler.

08-02-2018, 03:15 PM	#1
MooLard Private First Class 28 Rep 151 Posts Drives: 335d touring Join Date: Dec 2015 Location: Bucks, UK iTrader: (0)	Leaking intercooler Hi there Next fault after several others appears to be the intercooler. I have been trying to trace an oil leak by cleaning the underside of the engine and tray and this evening checking again for fresh oil. I have replaced the boost pipe seals and it’s a bit clearer now, it seems to be coming from the intercooler core to plastic end cap join on the exit side, has anyone seen this or had this happen to them before? The car doesn’t feel slower as in loosing boost, bit harder to tell on warmer days. Can I be mistaking this for a leak somewhere else? Recent repairs include transmission oil pipe replacement, valve cover gasket replacement, small turbo solenoid, map sensor, and boost pipe to intercooler seals. All over the course of eight weeks too... Thanks in advance, __________________ 2016 435xd GC, MTC intercooler, centre and back box deletes, GKR stage 2 remap, methanol injection, H&R lowering springs. To do: wash it.
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08-02-2018, 08:24 PM	#2
Owen81 Lieutenant 83 Rep 432 Posts Drives: 335d, 17/22 TDI Join Date: May 2015 Location: Alberta, Canada iTrader: (0)	There are seals on the exit side as well, did you do those? I had oil seeping out from the silcone hose to hard pipe section on that side of the engine as well. This would be easy to see as there will be a stream of residue originating from that connection, down to the intercooler connection.
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08-02-2018, 10:46 PM	#3
MooLard Private First Class 28 Rep 151 Posts Drives: 335d touring Join Date: Dec 2015 Location: Bucks, UK iTrader: (0)	H thanks for the reply, yes I’ve replaced the seals on the exit of the intercooler side: the aluminium pipe that goes up to the inlet manifold. The leak looks to be coming from where the fan shroud meets the inside of the intercooler. __________________ 2016 435xd GC, MTC intercooler, centre and back box deletes, GKR stage 2 remap, methanol injection, H&R lowering springs. To do: wash it.
	Appreciate 0 Quote