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repairing intercooler: free (almost)
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Posted by TML [Email] (#2212) [Profile/Gallery] (more from TML) on Tue, 22 Nov 2005 13:58:14 Share Post by Email
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After identifying the source of my boost leak as the intercooler, I proceeded to take it out, repair it and re-install it. All told, 3 hours work. The aluminum crimps holding the headers on had spread, causing partial separation. After seeing this, I strongly recommend anyone to pressure test their intercooler system regularly. Small leaks could easily be robbing you of power without you realising it.

The repair:
Unbent the remaining crimps and removed the header. Cleaned the seal, the header and area on the intercooler where the seal goes. Applied silicone to the intercooler, applied the seal. Applied silicone on the seal. Put the header back in place, re-crimped using a combination of wide mouth vice grips and standard pliers. Repeat for other side of intercooler. I used black titanium reinforced silicone caulking, which is 50% more flexible and more adhesive than regular silicone caulking. I expect this fix to be better than new, and last the life of the car.

Tips for removing intercooler:
-remove the nuts securing the condenser to the intercooler
-remove the oil cooler from the radiator (if applicable to model)
Everything is pretty self evident.

posted by 142.179.15...
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