Intercooler failure

[shezlee]

Not wanting to cause a panic but the information needs to be checked on your own A2 TDI

I was at Stealth Racing on Tuesday 18th for a remap to our A2 TDI something some of you have already undertaken.

Vince is such a great bloke and explaines everything and what is written here has nothing to do with Vince or Stealth Racing its just that they spotted the fault on our A2.

Before they start the remap they do some basic checks to see if your A2 is OK; Ours was not and hence this post.

The intercooler is splitting around the connections to the end caps; the end caps are plastic and the intercooler is clipping to them (would have been better if the end caps clipped to the intercooler). Vince may be able to get a replacement made from Forge with the end caps integrated; he will let me know in the new year.

You can buy a replacement but there are 2 for the TDI 75 and you would need to check, to replace the unit is about 4 hours labour so for me and our A2 we have to wait and hope Vince can get one as I have said before we plan on keeping the A2 for some time and its not something I what to keep replacing.

[Skipton01]

This could turn out to be a blessing in disguise:

It is great news that Vince spotted the failing intercooler before any work was done and testament to his skills.

It might be worth getting in touch with Allard Tuning in Gloucester, whi can definitely make you a replacement intercooler, and probably do you an uprated version into the bargain. Doing this will reap benefits when you do eventually get a map on the car and is something I'll be doing in the near future.

It is worth people checking their own A2s for impending intercooler failure thought.

For those that don't know, the intercooler is the small radiator like thing to the left of the main radiator, so check the inlet and outlet pipes from there.

Cheers,

Mike

[shezlee]

I will add a few pictures when I get a free moment.

Here they are: -

The Original one
http://i237.photobucket.com/albums/ff92/shezlee79/intercooler.jpg

View from above
http://i237.photobucket.com/albums/ff92/shezlee79/intercooler_b1_m1.jpg

View from the side-ish
http://i237.photobucket.com/albums/ff92/shezlee79/intercooler_b2_m2.jpg

[tdiman]

Same thing happened to my A4, the ring seal 'escaped' from between the ally bit and the plastic bit where they clamp over each other, it took a while to get a new one (non vag of course at stealer prices) got one for £99, great fun scaring pedestrians with my 'steam train impressions' in the meantime he he he

[shezlee]

I have three options

1, have a direct replacement £200 + VAT
2, have my IC modified to incorporate alloy end caps £265 + VAT
3, have a custom IC made £390 +VAT

All take about 4 hours to fit and this needs to be added to the total cost £200 - £400 depending on where you go.

We chose option 3 on the grounds that we would need to hire and other car whilst ours is having the work done.

Hopefully if all goes well and she can be remapped.

[Skipton01]

Custom intercooler eh? Sounds good and hopefully, you'll get a better map because of it too. Who is making it for you, not Allard by any chance?

Cheers,

Mike

[shezlee]

I think it being made by forge-motorsport Vince from Stealth Racing is handling the source and install.

With remap is costly but what's a few hundres pounds.

[shezlee]

Well its fixed and shiny...

Firstly the old broken one

http://i237.photobucket.com/albums/ff92/shezlee79/oldic_2.jpg

http://i237.photobucket.com/albums/ff92/shezlee79/oldic_1.jpg

Now the new shiny one

http://i237.photobucket.com/albums/ff92/shezlee79/newic_2.jpg

http://i237.photobucket.com/albums/ff92/shezlee79/newic_1.jpg

All in one piece will put the figures in the other thread.

[Colin]

That looks a seriously well put together piece of kit, far better than the original. The standard of workmanship that has gone into it, looks absolutely superb. Can't wait to see how you get on with a remap and the new horses.

[d4v1d sm4rt]

thanks for the excellent post, the new one looks a real work of art, shame its hidden away. Mine blew shortly after getting it chipped, so it is worth getting it done, luckily it was under warranty.!