Slightly stressed out xmas eve.

 

Some how last night at 3.5k rpm my Intercooler unzipped itself on the LH side.

 

Sounded like a massive dump valve going off followed by the car losing power (Obviously) and then running very rough.

 

Started it up this morning on stands to listen to where it was coming from only to find the clips holding the plastic end of the intercooler had popped out from the aluminium core clips.

 

Anybody ever heard of this happening on VAG genuine parts before? its only 18 months old too.

 

And obviously any thoughts on getting it back together successfully?

 

Any ideas or guides anybody knows off to even get to the intercooler to fix it?

 

Running Standard boost?

 

TBH if it's 18 months old it's a warranty job no?

Otherwise it looks like either a manufacturing fault or poor quality materials.

 

I'd be replacing not fixing that.

Yep its all standard apart from EGR delete.

 

I spoke to garage who fitted the intercooler all parts are only 12 month warranty even though its a genuine part so i'm stuffed.

 

ECP is£113 for a new one. just have to figure out how on earth to get the damned thing out now.

Bumper off job unfortunately.

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Headlights out, bumper off.  If you've got the right tools (2.5mm + 3mm torx bits, jack & jackstands etc) and you're reasonably competent you can do it in under 6 hours following an IC swap guide for a MKV Golf (which isn't quite the same but near enough).

 

Warranty on the part should be 2 years.  The 12 months is probably for the garages labour component.  As the garage purchased the parts on your behalf they should be making a parts claim for you.  Double check with VW as to the correct warranty period.

 

Also, think about fitting a bigger IC like a Golf R unit (might require some faffing with hose ends) - there a s cheap as chips 2nd hand.

Which forum can I get the golf guide from?

When you say faffing with the hose ends how much or is it just a case of twisting them to fit the correct orientation?

Or worse?

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Which forum can I get the golf guide from?

When you say faffing with the hose ends how much or is it just a case of twisting them to fit the correct orientation?

Or worse?

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It varies. 

Generally it's just a case of removing the bayonet / o-ring fitting off the hose end where it plugs into the IC and substituting some decent hose clamps.

 

I seen people on forums complain the original hoses aren't long enough (how?) but I get the feeling they either removed length from the hose or fitted aftermarket charge pipes that weren't quite right for the car.

 

If you are using the stock hoses that come with the replacement IC (that's how I bought mine 2nd hand) there's a possibility that the bayonet fitting on the turbo discharge hose won't line up but you can check this as soon as you have the undertray off so it isn't a huge disaster.

 

For the guide, just google Golf intercooler install / guide / DIY.  There's one at Forge and APR and probably SPM

 

http://www.vwwatercooled.com.au/forums/f155/diy-s3-golf-r-intercooler-installation-96566.html

 

 

 

http://www.forgemotorsport.com/media/FMMK5FMIC.pdf

 

http://www.golfmk6.com/forums/showthread.php?t=46452

Looking at the guide it looks as if taking the fittings off the IC end of the charge pipes is the best way to get them to fit and as you say decent hose clamps.

If I can figure out which size.

I'm guessing the difference between the octy and mk v golf IC is the thickness and no of rows so slightly taller but not wider and should still fit using the original mountings.

I need to fit it AsaP so don't want any unforeseen problems cropping up.

But also deffo think a better IC is the way to go if I'm stripping the front anyway.

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It took me just over an hour to get to this stage.

You can now see how the intercooler unzipped.

I'm ready for the 2nd hand IC to turn up before I do more. But all the bolts are loosened ready to go. I lost count but probably 20 or so to get the structural stuff off and put of the way so I can separate the cooler/rad pack from the car and remove the IC and re build the front end.

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All finished. I think just over 4 1/2 hours start to finish I reckon I could do it in 3 1/2 easy now I know what to do.

But here is the removed IC clearly not good.

Fitted a 2009 model IC much better design though.

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