Found my boost leak

[V8weight]

I decided to jack my car up and check out all of my intercooler hoses and clamps today after doing some data logging and finding my actual boost to be lower than my requested. I started with the passenger side, removed all three hoses, cleaned them up with lacquer thinner and reinstalled them. When I got to the drivers side I noticed quite a bit of oil around the seam where the intercooler core meets the lower tank. Here goes my afternoon. So I pulled the drivers side intercooler and cleaned it up and pressure tested it, and sure enough there was a pinhole in the seam. I'm pretty sure my warranty co. will cover a new cooler, but I'm just tired of driving loaner cars. Plus, every time I get my car back I find missing bolts that were left off during the repair. So I decided to try and seal the seam with some JB Weld. I know it's corny, but if it doesn't hold up, I'll either bring the car in and have it replaced, or see if the warranty co. will allow me to install a new one and flip for the part. Does anybody know what a new intercooler costs?
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[mattsimis]

Ive heard of people sealing the plastic capped 2.7T stock I/Cs with JB Weld before. It works, dunno if anyone left it like that long term though.

[awtst3.a6]

What intercoolers? They might be from rubbing on the driver side if they are after market which they look like. I noticed rub marks on my intercooler yesterday pulling the bumper off on the driver side. Try putting the incooler more solid in there. Add some clips or zip ties. The intercoolers aren't held in there real tight.

[V8weight]

What intercoolers? They might be from rubbing on the driver side if they are after market which they look like. I noticed rub marks on my intercooler yesterday pulling the bumper off on the driver side. Try putting the incooler more solid in there. Add some clips or zip ties. The intercoolers aren't held in there real tight.

These are the stock intercoolers, this is an RS6, not a 2.7t. This wasn't caused by rubbing, there was actually a pinhole in the seam where the core is soldered to the tank. I would assume there was some impurity in the metal that worked it's way through the solder over time. I don't plan on leaving it like this for long, just until I can get a hold of my warranty co. and get a replacement coming. I'm hoping they will allow me to replace it myself, as I'm a little tired of my car sitting at the dealership 1-2 weeks out of every month.

[awtst3.a6]

These are the stock intercoolers, this is an RS6, not a 2.7t. This wasn't caused by rubbing, there was actually a pinhole in the seam where the core is soldered to the tank. I would assume there was some impurity in the metal that worked it's way through the solder over time. I don't plan on leaving it like this for long, just until I can get a hold of my warranty co. and get a replacement coming. I'm hoping they will allow me to replace it myself, as I'm a little tired of my car sitting at the dealership 1-2 weeks out of every month.

Hehe, Yeah i thought it was one because I saw the 2 intakes... haha.. I was just wondering because I knew they were rs4/rs6 I/C's or aftermarket by the weld. I had a question for you. I think it is my meth pump kicking on that I am hearing but how do you test the intercooler? I have everything for pressure testing but don't know how to do it on the intercoolers. Just the car through MAF. Thank you

P.S. I wonder if it can be rewelded around the intercooler?


Sam K