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Thread: replacement Intercooler options

  1. #1

    replacement Intercooler options

    Hello Everyone,
    Im looking for a little advice. My intercooler has split (2002 1.4TDI AMF, 172000 miles). It had been whistling for 2 years on and off (didnt know the intercooler was the cause of it) but now its more like a hoover when i accelerate. No warning lights or limp home but big loss in power.
    Im wondering what options for replacement exist. Cost is a factor here. The car is in good nick and Ive owned it since 40k and serviced it religiously but realistically is only worth about 500. Recently all the shock absorbers (FSDs) were replaced under warranty and new front springs (spidan) fitted. But its due a timing belt too and the gearbox is notchy as hell and sometimes very difficult to get into 3rd (have to go back to 2nd or 4th and try again). Its been remapped to about 100bhp or so i think. Last week a friend driving behind me said it was very smokey when accelerating, but maybe thats due to the then just leaky intercooler? Im in Ireland too.
    Anyway. If someone could chime in with what options exist in the way of replacement intercoolers and their cost that would be really appreciated. Trying to decide whether its worth undertaking the expense of repair.
    Many thanks
    Nick

  2. #2
    Join Date
    Apr 2014
    Location
    Halifax
    Posts
    105
    I assume that timmus' all alloy option is out of the price range but, other than an Audi one,A2Steve recently mentioned buying an intercooler from a Freelander 1 as it seemed to be the same size. Perhaps you could PM him for advice.

  3. #3
    Your best bet is to go for a Mk1 Freelander - they are pretty much identical in size to the A2 one, just a little thicker in the core (= more cooling) and will need a little work in adapting the mounting points, but it's by far the cheapest way to do it. They can be had off the famous auction site for 50 and have welded end caps, meaning no more splitting or blowing.

    As to your smoke, it's almost certainly down to the intercooler and will likely go away when the new one is fitted. And gears - I reckon your box will be in need of a top up - it's amazing how many owners and garages think its a sealed system. It's not - A2s are famous for weeping from the drive shaft outputs and over a decade, the box will run very low. There's guides on here how to change the oil (if you've got a jack and stands, you can do it yourself). Then, I'd give the gearshift cables an alignment too and I bet your box will feel silky smooth again.

    I'm tempted to say get on the ferry and I'll sort it for you, but I really haven't the time these days and I'm sure there's places over there who can sort you out. Cambelt and water pump kit is around 100 plus fitting and isn't too hard a job either.

    What you say the car is realistically worth is only relevant if you've made up your mind to chip it in. From what you say, it's a good little car and with 3-400 spending on it, you'll have a car that'll give you reliable service for many, many years to come.
    WAS : TDI 75 SE 2001 (Little Tank)
    NOW : TDi 90 Sport, OpenSky, Winter Pack, ISOfix, fogs, climate, full electric glass, RNS-E, IceLink, Audi BT phone & red leather! K&N filter, Pentagon Supaglass, black headlining, cruise & Audi PDC, GALA, S-style mirrors & TT road and steering wheels.(The NEW Tank).

  4. #4
    Quote Originally Posted by nick4tl View Post
    Hello Everyone,
    Im looking for a little advice. My intercooler has split (2002 1.4TDI AMF, 172000 miles). It had been whistling for 2 years on and off (didnt know the intercooler was the cause of it) but now its more like a hoover when i accelerate. No warning lights or limp home but big loss in power.
    Im wondering what options for replacement exist. Cost is a factor here. The car is in good nick and Ive owned it since 40k and serviced it religiously but realistically is only worth about 500. Recently all the shock absorbers (FSDs) were replaced under warranty and new front springs (spidan) fitted. But its due a timing belt too and the gearbox is notchy as hell and sometimes very difficult to get into 3rd (have to go back to 2nd or 4th and try again). Its been remapped to about 100bhp or so i think. Last week a friend driving behind me said it was very smokey when accelerating, but maybe thats due to the then just leaky intercooler? Im in Ireland too.
    Anyway. If someone could chime in with what options exist in the way of replacement intercoolers and their cost that would be really appreciated. Trying to decide whether its worth undertaking the expense of repair.
    Many thanks
    Nick


    Hi Nick

    Sorry to hear about your failed intercooler on a much cherished A2.

    One option for replacement could be fitting one of the intercoolers that are likely to be available soon when some members change over from the new batch of all-alloy intercoolers.

    I have ordered one of these and therefore would have a discarded OEM unit available. I don't know a date for the work yet but if you are able to wait, I can find out a time-frame and PM you some details. I have checked with timmus that this is a suitable thing to do.

    Good Luck

    Hilary
    2005 (05) 1.4 TDI75 Special Edition Dolphin Grey

  5. 2 users that liked this post:

    nick4tl (06-11-2017), Special edition (05-11-2017)

  6. #5
    Join Date
    Apr 2010
    Location
    Lancaster, UK
    Posts
    4,928
    Quote Originally Posted by Skipton01 View Post
    Your best bet is to go for a Mk1 Freelander...
    Whilst this option is looking promising, I think it's possibly a bit early to be declaring it as the best bet. Unless I'm mistaken, nobody has yet done it. The boost input and output are angled very differently, which may mean that custom hosing needs to be manufactured. The bracketry also doesn't align, so a solution needs to be found for this issue. There are also the downsides of a thicker core to consider, as discussed in Sections 5 & 6 of the TDI120 thread.

    Quote Originally Posted by YorkshireHill View Post
    One option for replacement could be fitting one of the intercoolers that are likely to be available soon when some members change over from the new batch of all-alloy intercoolers.
    This could definitely be a cheap option for you. 24 all-alloy intercoolers are about to be shipped to various members across the UK and other European countries. Plenty of them will be fitted in the near future, thus releasing lots of OEM units. Yes, the OEM unit has the documented weakness that leads to failure (as has happened in your case), but it's a perfect fit and there should soon be plenty of them available on the second-hand market!

    Cheers,

    Tom
    Last edited by timmus; 05-11-2017 at 07:10 PM.
    A2 Retrofitting & Upgrade Service Offered: Cruise Control, DIS, Bose, Rear Electric Windows, Multifunction Steering Wheel, Heated Seats, Auto-Dimming Mirror, Bluetooth, Rear Speakers, Double-DIN Dash, RNS-E, Front Fog Lights, Lumbar Support, Komfortblinker, Convenience Unit Replacement, Key Programming, and much more...

    Click here to reserve Colour DIS

    All-alloy intercoolers are complete!


  7. #6
    Join Date
    May 2013
    Location
    Aberdare, South Wales
    Posts
    4,023
    I haven't posted anything on this yet because i'm yet to plumb it in but it's certainly not a plug and play option. So far i've had to grind away the redundant lobes and i'm yet to make a bracket to support the bottom of the unit. I will do a write up but want to test its function first.

    As Tom has mentioned the freelander unit is twice as deep as the standard unit so unless you are running a hybrid/bigger turbo as I am then it may even be a power hindrance in the real world due to increased lag.
    Steve
    0779zero965448

    Lots of parts/spares for sale - please click the link

    http://www.a2oc.net/forum/showthread...equest-A2Steve



    Project TDI150 underway

  8. #7
    Join Date
    Jan 2014
    Location
    Huntingdon Cambs
    Posts
    272
    There is a new genuine Audi intercooler on Ebay at 250
    https://www.ebay.co.uk/itm/NEW-GENUI...4AAMXQVT9S2u9g
    2004 1.4 TDI 75, 74k miles, Revo Remap. Crystal Blue, Cruise Control. ATE Power discs and ceramic pads

  9. #8
    If you want cheap, there's an aftermarket one here for 60 brand new:

    http://www.ebay.co.uk/itm/Hella-AIR-...MAAOSw5n5Zfi6f

    Or, grab a used genuine one for 50:

    https://www.ebay.co.uk/itm/AUDI-A2-2...gAAOSwGUBZ~0bq
    WAS : TDI 75 SE 2001 (Little Tank)
    NOW : TDi 90 Sport, OpenSky, Winter Pack, ISOfix, fogs, climate, full electric glass, RNS-E, IceLink, Audi BT phone & red leather! K&N filter, Pentagon Supaglass, black headlining, cruise & Audi PDC, GALA, S-style mirrors & TT road and steering wheels.(The NEW Tank).

  10. Users that liked this post:

    froggy (17-11-2017)

  11. #9
    Hi All, Thanks for the responses. I have a sense of some options now anyway. I'm coming around to the idea of holding on to the old brute for a while longer. The thoughts of kicking tyres and taking a punt in the used car market fills me with far more dread than thinking about the possible risk of sinking a bit more into a car that has, although beginning to show its age of late, been thoroughly reliable over 10 years of ownership.

    Hopefully the extra cost of the intercooler added to the new timing belt and waterpump that were coming up anyway wont be too bad.

    I'll ring around a few reputable local garages tomorrow to get some quotes.

    If anyone has gone for an aftermarket intercooler and not had it blow up in 18 months do let me know I think thats the path I will probably have to go to keep the cost down. Just wondering if there is any quality difference between nissens, hella, vemo, Van Wezel etc

  12. Users that liked this post:

    E T Oddie (06-11-2017)

  13. #10
    Join Date
    Jan 2014
    Location
    Wakefield, Yorkshire.
    Posts
    2,866
    Thankyou Hilary for offering your intercooler... nice gesture !. Hilarys is a 75bhp tdi but if anyone needs a 90bhp intercooler mine will be available for free in the next few weeks. I will ask Rob and Marcus at WOM, if they don't mind, to give it the once over to make sure its fault free before handing it over.
    Last edited by Special edition; 06-11-2017 at 08:13 PM.
    Cherry Red Tdi 90

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