Intercooler failure

shezlee

Member
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

Well-Known Member
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

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

Here they are: -

The Original one


View from above


View from the side-ish
 
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tdiman

Past Member
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

Member
Update

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

Well-Known Member
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

Member
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

Member
Intercooler replaced

Well its fixed and shiny...

Firstly the old broken one





Now the new shiny one





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

A2OC Donor
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

A2OC Donor
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.!
 
hello, yes but i think im gonna hold out for a cheaper one; should get one 50 quid if that, as ive picked my parts up for PEANUT money off ebay and few other sites, had quotes of £750+ for the parts from ripoff scrap yards and even some mugs especially these so called "specialist" breakers selling used parts for more than there new, you could understand if it was a body panel, as it saves you money in sprayin costs if u dont know anyone, but mechanical parts is a joke.

nirro "specialist" scrappers in london, used starter motor 65quid 3 month warranty

new reconditioned one with 12month warranty 49 quid

anyway here's the link;

http://www.carcooling.co.uk/products/Intercooler_Audi_A2_1422_cc_2000_03_02_00_12_03_1_4_TDi_Man_Auto_vehicles_with_or_without_A_C_280_130_40mm_If_original_intercooler_has_19mm_thrust_sensor_a_new_12mm_sensor_must_be_bought_from_Audi_14Ai307-91168-128.html


just make sure you shop around ive spent the best pat of a few hrs over the last week searchin for them, missed a bumper on ebay complete brand new sold for 100 quid yesterday



thanks
 
I had exactly the same story so well worth checking your intercoller first as it saves two long trips. I bought a new one from Eurocar car parts for £154 all in inc delivery. Took me 2.5 hours to fit but it is a bit of a fiddle.
 

girindor

A2OC Donor
Help?

hello, yes but i think im gonna hold out for a cheaper one; should get one 50 quid if that, as ive picked my parts up for PEANUT money off ebay and few other sites, had quotes of £750+ for the parts from ripoff scrap yards and even some mugs especially these so called "specialist" breakers selling used parts for more than there new, you could understand if it was a body panel, as it saves you money in sprayin costs if u dont know anyone, but mechanical parts is a joke.

nirro "specialist" scrappers in london, used starter motor 65quid 3 month warranty

new reconditioned one with 12month warranty 49 quid

anyway here's the link;

http://www.carcooling.co.uk/products/Intercooler_Audi_A2_1422_cc_2000_03_02_00_12_03_1_4_TDi_Man_Auto_vehicles_with_or_without_A_C_280_130_40mm_If_original_intercooler_has_19mm_thrust_sensor_a_new_12mm_sensor_must_be_bought_from_Audi_14Ai307-91168-128.html


just make sure you shop around ive spent the best pat of a few hrs over the last week searchin for them, missed a bumper on ebay complete brand new sold for 100 quid yesterday



thanks
Thanks for the tip, my intercooler needs to be replaced and I am thinking of buying this one: http://www.carcooling.co.uk/products/Intercooler_Audi_A2_1422_cc_2000_03_02_00_12_03_1_4_TDi_Man_Auto_vehicles_with_or_without_A_C_280_130_40mm_If_original_intercooler_has_19mm_thrust_sensor_a_new_12mm_sensor_must_be_bought_from_Audi_14Ai307-91168-128.html

However, they say that
If original intercooler has 19mm thrust sensor a new 12mm sensor must be bought from Audi
I do not understand this... Does this mean I can just go ahead and buy this intercooler, but might need to buy some extra part separately from Audi? How do I check this?

Thanks for your help!
Robin
 

timmus

A2OC Donor
Thanks for the tip, my intercooler needs to be replaced and I am thinking of buying this one: http://www.carcooling.co.uk/products/Intercooler_Audi_A2_1422_cc_2000_03_02_00_12_03_1_4_TDi_Man_Auto_vehicles_with_or_without_A_C_280_130_40mm_If_original_intercooler_has_19mm_thrust_sensor_a_new_12mm_sensor_must_be_bought_from_Audi_14Ai307-91168-128.html

However, they say that
If original intercooler has 19mm thrust sensor a new 12mm sensor must be bought from Audi
I do not understand this... Does this mean I can just go ahead and buy this intercooler, but might need to buy some extra part separately from Audi? How do I check this?

Thanks for your help!
Robin
Yes, that's precisely what it means.
The thrust sensor size was changed around 2003, I believe. Pretty much all A2 intercoolers now have the hole for the newer size of sensor. Given that your A2 was built in 2001, I think it's likely that you'll need to buy a sensor of the new size. They're a fairly cheap part, so it won't add much to the cost of the repair.

Tom
 

girindor

A2OC Donor
Thanks for your help!

Yes, that's precisely what it means.
The thrust sensor size was changed around 2003, I believe. Pretty much all A2 intercoolers now have the hole for the newer size of sensor. Given that your A2 was built in 2001, I think it's likely that you'll need to buy a sensor of the new size. They're a fairly cheap part, so it won't add much to the cost of the repair.

Tom
Thanks, I will get that 12mm thrust sensor from Audi then. Have ordered the Intercooler, hopefully it will be ok!
 

spike

Well-Known Member
Thanks, I will get that 12mm thrust sensor from Audi then. Have ordered the Intercooler, hopefully it will be ok!
Not sure if the new thrust sensor comes with a new O.ring seal but if not, its worth getting a replacement (cost approx 70p and the sensor, £50)

Cheers Spike
 

robert

Member
Wow, that forge intercooler is a proper job. The original crap is just waiting to break as the aluminium is bent over the plastic ends. The small form factor doesn't give any structural strength and the weight and stress of the lower hose make it a time bomb. My intercooler blew and looked like a copy of shezlees lemon. It began with a fluttering whistle, very easy to hear when accelerating close to a wall/hedge with the window down. A while later when accelerating in 5'th gear the limp mode set in at 100km/h (70mph) and I never got any engine lamp.

I don't have the $$$ nor the energy to mod and squeeze the larger forge intercooler as you must do it so well to not get problems up the road. For sure I didn't want another crappy Audi part, specially for £ 345 so I ordered the cheap intercooler in this thread. The next day they cancelled the order with no explanation. It was stated as £ 80 but after a few emails they wanted £ 170 to ship it. I bailed out as I found they had more web stores with other prices/part numbers for the same products so I figured they are too suspicious to hand money to.

Instead I took the jig saw and started to trim my old intercooler as that would make an instant fit if I just replace the plastic ends with aluminium which is what Audi should have done in the first place. I made all parts from an old Mac Pro except the pipe which I got from the scrap yard to make the hose connection. The different alu qualities was good friends under the tig, naturally after plenty of cleaning and sanding. The difficult part (and boring job) was to take away the pesky front and get the intercooler out and back in. All in all, I was faster back on the road compared to if I had to wait for the shipment and I have a far better intercooler.

Fix two intercoolers with each Mac Pro:
1.jpg
3.jpg
4.jpg
I made holes in the plastic frame to get to the screws:
5.jpg
 
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