Just had the same issue. Because there was so little oil in the intercooler itself (only misting form one corner) I decided to prise off the tank and investigate. I found corrosion behind the O ring where water and salt had got in which in turn swelled up pushing the O ring away from the core. The situation of the intercooler at the front of the car and at the bottom of the grill, exacerbates the problem. Add that to 12 years of driving and the inevitable has happened . For that reason a used part is not advisable, it’s new or repair only.
The best way iv found to repair blown out end tank seals is to first clean the intercooler inside and out with acetone. I then block any outlets with tapered rubber bungs apart from one which I attach to an industrial vacuum cleaner . 80% of the time the vacuum will pull the seal back in and pull the end tanks in tight to the core. I can then carefully tighten the crimps around the tanks and job done. For the 20% that it doesn't work on, I cut the end tanks off and make new aluminium tanks and weld them on. Still cheaper than buying a new one.
Hey Anthony can't you pressurise it like a tube with a pump a nd detergent and find the exact pin hole..I fixed a hole with a black buttyl product from that high quality silicone brand after cleaning with alcohol cleaner.. worked a treat
I have a lot of oil on intake charge pipe and on entry of buttlerfly housing on my x3 e83 turbo diesel the charge pipe is full of oil the car runs well but smokes when on tickover
Hi Antony fully agree re wreckers (scrap yards uk) not always far cheaper. Also you don't know if good so poor man might pay three times. I would clean up brake cleaner. Light sanding to give a key grip. Use a 2 part appoxy that's good for vibration heat. Not worth 1000 ASD for leak keep an eye on it. In UK presently spoilt for motor factors. Same genuine parts huge price variants. Being on pension shop around all on line found 50% cheaper to get spares from Germany delivered. As normal you thrown it out see what guys say. I've always got my 2 part various appoxy when I'm traveling. Cheers Bob
Good video. I’d would clear away oil residue, clamp the aluminum fingers a little bit more and then seal it all up. Not worth $1000 Aussie dollars for a new one. and I totally agree, most wreckers have shit stuff and you are only buying someone else’s problems. I’ll keep watching with interest on these good vids. Thanks again 👍🏻
Just had the same issue. Because there was so little oil in the intercooler itself (only misting form one corner) I decided to prise off the tank and investigate. I found corrosion behind the O ring where water and salt had got in which in turn swelled up pushing the O ring away from the core. The situation of the intercooler at the front of the car and at the bottom of the grill, exacerbates the problem. Add that to 12 years of driving and the inevitable has happened .
For that reason a used part is not advisable, it’s new or repair only.
The best way iv found to repair blown out end tank seals is to first clean the intercooler inside and out with acetone. I then block any outlets with tapered rubber bungs apart from one which I attach to an industrial vacuum cleaner . 80% of the time the vacuum will pull the seal back in and pull the end tanks in tight to the core. I can then carefully tighten the crimps around the tanks and job done. For the 20% that it doesn't work on, I cut the end tanks off and make new aluminium tanks and weld them on. Still cheaper than buying a new one.
I found when re fitting the intercooler put the turbo pipe in first then the egr pipe, less strain on the unit to home it
Could you plug all the outlets and pressure test under water like you would a radiator. Say around 5 to 6 psi. Or would that blow the o ring worse.
how about clamping down slightly every tab applying extra pressure down on the o ring?
Hey Anthony can't you pressurise it like a tube with a pump a nd detergent and find the exact pin hole..I fixed a hole with a black buttyl product from that high quality silicone brand after cleaning with alcohol cleaner.. worked a treat
Im trying Alumaweld/JB Weld on my semi truck intercooler
I heard crimp it tighter , but I'm going to check a radiator place tomorrow to find out how much to check it out
I have a lot of oil on intake charge pipe and on entry of buttlerfly housing on my x3 e83 turbo diesel the charge pipe is full of oil the car runs well but smokes when on tickover
Hi Antony fully agree re wreckers (scrap yards uk) not always far cheaper. Also you don't know if good so poor man might pay three times. I would clean up brake cleaner. Light sanding to give a key grip. Use a 2 part appoxy that's good for vibration heat. Not worth 1000 ASD for leak keep an eye on it. In UK presently spoilt for motor factors. Same genuine parts huge price variants. Being on pension shop around all on line found 50% cheaper to get spares from Germany delivered. As normal you thrown it out see what guys say. I've always got my 2 part various appoxy when I'm traveling. Cheers Bob
Is it normal to find oil in the interviewer? Does indicate something ?Thank you
If I was going to replace it anyway, I'd get some vice grips and try to squeeze the two corner tabs a little tighter.
We actually did something that worked
@Fourby4Diesel what worked on it please mate? I have this problem now
Good video. I’d would clear away oil residue, clamp the aluminum fingers a little bit more and then seal it all up.
Not worth $1000 Aussie dollars for a new one.
and
I totally agree, most wreckers have shit stuff and you are only buying someone else’s problems.
I’ll keep watching with interest on these good vids. Thanks again 👍🏻
My car has same problem
👌👍🤘😎🇦🇺🍻🙏