Leaking Supercharger Intercooler Symptoms

[hckymstr19]

OK so I installed my KC about a week ago and literally 3 days after, for the first time I went to start the car and it stalled but then fired up right after. Didn't think too much until I let the car sit for a few hours and went to start and it was a very rough start and rpms stumble real low for a sec or two and then it evens out. Now I assumed I may have a leaking intercooler but when I check vcds during these rough starts it doesn't show a misfire at all and after this, the car drives fine. And this most recent time after the gum for an hour an a half, the engine started real rough and then the idle was extra rough once it evened out, like so rough the car actually rocked back and forth rather hard, way more than usual but once I started driving it was fine and drove great.

So I have realized it really only happens after I drive it for a while and then let it sit for an hour or two and try to start it again because if I let it sit over night it starts up fine. I was actually hoping to see misfires so I could narrow down what the issue is but without misfires, I'm not sure.

I'm thinking about the KC install and I cut into the Ac circuit and supercharger circuit both which are separate circuits from the engine. So if the ac has major issues that shouldn't effect starting the engine or rough idle, and even if the supercharger circuit had no fluid in it, the car should still start up fine, right? But the only thing that makes logical sense to why the engine would coincidentally have start up rough idle issues after the KC install would be somehow that fluid is leaking into the engine somehow right?

So anyone that has any ideas or experience with knowing they have a leak please chime in, plus I think this is a good thread since this issue has been cropping up for more people. Let me know your thoughts guys.

[TheAsset]

If the car is under warranty I'd take it to the dealership.

[whiped]

If the car is under warranty I'd take it to the dealership.

With the KC and all his other mods? They'd tell you to go pound sand lol.

It might be condensation forming on the IC cores and dripping down if you aren't loosing any coolant.

This would explain why it happens when parked for a short time but not a long time. That or it could be your cats.

You should be able to see the misfires at idle, when my cats are clogged I can feel the misfires when I first start it up [:(]

[hckymstr19]

With the KC and all his other mods? They'd tell you to go pound sand lol.

It might be condensation forming on the IC cores and dripping down if you aren't loosing any coolant.

This would explain why it happens when parked for a short time but not a long time. That or it could be your cats.

You should be able to see the misfires at idle, when my cats are clogged I can feel the misfires when I first start it up [:(]

Yea it's just everytime I've logged during the rough startups, it surprisingly shows 0s across the board which is the odd part. And Condensation does make sense, but I feel loe or others with KC would experience this regularly as well if condensation was an issue. And every time I check I don't seem to be losing any coolant in the supercharger circuit(divorced system).

But if it is condensation inside dripping, is there anything that I could even do for that?

[whiped]

Turn off the AC for a bit before parking to let it warm up? No idea if that is actually it, I just know Loe gets condensation on his reservoir so figured it might do it internally too. Doubt it would be enough to cause real issues though.

How are your cats/plugs? Are you running any Ethanol?

[hckymstr19]

Turn off the AC for a bit before parking to let it warm up? No idea if that is actually it, I just know Loe gets condensation on his reservoir so figured it might do it internally too. Doubt it would be enough to cause real issues though.

How are your cats/plugs? Are you running any Ethanol?

No ethanol, plugs are ngk 9s about a month or 2 old, I get a couple misfires here and there while driving, but drives great. I have no idea about my cats, how would I check, I remember reading something about checking voltage form o2 sensors?

[jfootlong24]

With the KC and all his other mods? They'd tell you to go pound sand lol.

It might be condensation forming on the IC cores and dripping down if you aren't loosing any coolant.

This would explain why it happens when parked for a short time but not a long time. That or it could be your cats.

You should be able to see the misfires at idle, when my cats are clogged I can feel the misfires when I first start it up [:(]


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[jfootlong24]

With the KC and all his other mods? They'd tell you to go pound sand lol.

It might be condensation forming on the IC cores and dripping down if you aren't loosing any coolant.

This would explain why it happens when parked for a short time but not a long time. That or it could be your cats.

You should be able to see the misfires at idle, when my cats are clogged I can feel the misfires when I first start it up [:(]

Wouldn't the cylinder be more than hot enough to have evaporate any condensation that would drip?


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[hckymstr19]

But if significant condensation builds up on the intercoolers inside and then when I go to start after like an hour, wouldn't upon trying to start up, that condensation would be forced into the cylinders which would cause an issue like this? Does that make sense? Kinda like running too much water in a water/meth injection and you get quenching? I don't know enough about that to be sure.

[jfootlong24]

But if significant condensation builds up on the intercoolers inside and then when I go to start after like an hour, wouldn't upon trying to start up, that condensation would be forced into the cylinders which would cause an issue like this? Does that make sense? Kinda like running too much water in a water/meth injection and you get quenching? I don't know enough about that to be sure.

I mean I guess anything is possible but I doubt it god knows how hot the cylinder gets but I'm in the same boat as you dropping my car off today to crown Motorsports to let it sit overnight and look into the cylinders to look for fluid, but we're going to experiment with the cores and have them zircotec coat them and see if that will hold them together


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[Chris@EPL]

No ethanol, plugs are ngk 9s about a month or 2 old, I get a couple misfires here and there while driving, but drives great. I have no idea about my cats, how would I check, I remember reading something about checking voltage form o2 sensors?

I doubt it is the issue, but for our tunes only CA 91 DP need the 1 step colder plugs. Every other set up DP, 93, E85 should all have stock plugs gapped to .026"

Not likely the issue, but may be worth switching out when you get a chance to see any difference. But after you dial everything in with the KC.

[hckymstr19]

I mean I guess anything is possible but I doubt it god knows how hot the cylinder gets but I'm in the same boat as you dropping my car off today to crown Motorsports to let it sit overnight and look into the cylinders to look for fluid, but we're going to experiment with the cores and have them zircotec coat them and see if that will hold them together


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Yea let me know what they find, yours at least seems to be pointing in somewhat of a direction and since you are losing some intercooler fluid which would seem to point toward a leak.

As for the condensation, I'm not saying it's them dripping into the cylinders, but my reservoir gets a crap load of condensation on it so I can only assume that's happening on the intercoolers inside the engine. And then just picture a reservoir that's coated in condensation, now put all that condensation on the intercoolers and you go to start your car and air is then being pulled/pushed into the cylinders and inevitably bringing all that condensation with it. But would that much water upon start causing the rough start, wouldn't that show misfires or no? I'm not sure from a tuning standpoint if the engine can have a rough start but not be misfiring if it's related to too much water or "quenching" so to speak.

[RWD2quattro]

stock plugs gapped to .026"
^^This.

[hckymstr19]

^^This.

I was going to go back to stock plugs anyways even though the plugs I'm using now are working fine. But you have to look at exactly what is happening and WHEN it happened. I installed the KC and then 3 days later I get start up issues. The KC should have absolutely no effect with start ups or spark in anyway, unless they are leaking somehow.

[hckymstr19]

OK so I started the car after letting it sit for 3 days over the weekend and it started up flawlessly with no roughness whatsoever. I'm going to replace the spark plugs because I was going to before anyways so we can eliminate that. But if that doesn't help, any other suggestions?

[p3u]

Pm'd you. I have the same exact issue and very similar setup. Would love to know if you found the issue and hopefully resolved it.

[mrb5_supra_wrx]

Pm'd you. I have the same exact issue and very similar setup. Would love to know if you found the issue and hopefully resolved it.

post it here for future reference others might need the help too

[Lensch09]

Has anyone else noticed the trend between killer chiller and cracked IC? I definitely have.

-DL

[whiped]

Has anyone else noticed the trend between killer chiller and cracked IC? I definitely have.

-DL

He cracked them before the KC too.

I think it is more pressure related...

[cspcrx]

Interesting reading. When I first heard about the KC this was a concern I had. Stressing the metal by having such a huge temperature differential.

[Loe]

there's no correlation or trend...

I've cracked these at stock cooling, then again with the AWE coldfront system, then again when I transitioned from the AWE to KC, and now just the KC. I run my car harder than most, much harder than most (daily driver that sees WOT a few times during my 45 minute highway commute, track almost every thursday, a few saturdays, and a few sundays). The environment of squeezing boost in a tiny blower pretty much creates an issue for the blower, however that may not even be the case as these have cracked at stock boost levels on stock cooling on other 3.0t platforms.

[EIAlfonso]

I had the same exact issues right after I installed my HX and went DP (both at same time).

Then after 3 weeks it started up and huge plumes of white smoke came out of the exhaust. Both IC's were replaced, I never knew why it happened to occur just after the DP/HX were installed and I may never know for sure but what you are saying sounds exactly as what was happening to me.

I've never had a KC installed.

[p3u]

Follow up question. If you suspect it is leaking how do you confirm? Seems like you'd leak fluid in the supercharger just by removing it regardless of their being a leak.

[whiped]

Your best bet to actually confirm is to disconnect the hoses on the front of the SC and pressure test the ICs.

Should be easy to do. I am not sure how much pressure they will hold but you should definitely know if there is a leak.

[JaB6]

For symptoms- Does the ECU enrichen the fuel mixture in response to the leaky intercoolers, as seen as rich condition when looking at lambdas?

[EIAlfonso]

It looks like I may be on my third set (second replacement) of intercoolers. My start up stumbled this morning and then saw quite a bit of white smoke out the back that quickly dissipated


What are the things that I can do after replacing to help the longevity?

Are the OEM the only real solution?

I have an additional HE and spray water with AME kit, what else as far as equipment can I change?

I'm on a 184 Crank APR Supercharger Pulley (about 3.2 ratio)

[theweebabyseamus]

Additional HX? Or larger HX?

[EIAlfonso]

Additional HX? Or larger HX?

I have an additional small HX from merc


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[Moose88x]

Haven’t really had an issue with this yet knock on wood, however I am installing a jokerz ported blower within the next week or so. Do you think I should purchase 2 new intercoolers for the new charger? It’s got around 20k miles on it. My current blower has around 99k on it. I’m currently APR UC with a 194/57 setup. I’m running the PLM kit with an expansion tank and I’m going to divorce the system when I swap the blower and do a carbon clean. Do you think this is a good preventative measure or just wait and ride it out?


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[theweebabyseamus]

I have an additional small HX from merc


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Maybe try a better HX setup and divorce with straight water? That’s all I got, I wouldn’t think you’d have too much of an issue spraying the water.

[EIAlfonso]

Maybe try a better HX setup and divorce with straight water? That’s all I got, I wouldn’t think you’d have too much of an issue spraying the water.

I may just divorce it and see if my temps come down, now to read up on how to divorce a system

[EIAlfonso]

Haven’t really had an issue with this yet knock on wood, however I am installing a jokerz ported blower within the next week or so. Do you think I should purchase 2 new intercoolers for the new charger? It’s got around 20k miles on it. My current blower has around 99k on it. I’m currently APR UC with a 194/57 setup. I’m running the PLM kit with an expansion tank and I’m going to divorce the system when I swap the blower and do a carbon clean. Do you think this is a good preventative measure or just wait and ride it out?


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I would just wait, never know Audi may revise the oem once again (I think they're up to F) or a better aftermarket cooler may pop up

[AdamInKC]

Curious, when other have had a supercharger cooler leaking, have you also had to replace spark plugs? I just replaced both coolers and all pertinent seals after a slow coolant loss, misfires at startup and under WOT. I took the car for a spin tonight and am still seeing misfires on cylinder 3 and the car going into 'protection' mode (EPC). I am looking to replace all spark plugs this weekend. Also, do you have to clear codes after removing the SC for any reason?

[Loe]

its best to replace the spark plug where the misfire occured, you don't have to replace all plugs unless they are all fouled or they are all at their time to be replaced. Clearing the code isn't necessary unless you have a CEL light present, but there will likely be stored codes if there was a missfire event prior to replacement and the CEL codes weren't cleared prior to replacement.

[brs2c]

Curious, when other have had a supercharger cooler leaking, have you also had to replace spark plugs? I just replaced both coolers and all pertinent seals after a slow coolant loss, misfires at startup and under WOT. I took the car for a spin tonight and am still seeing misfires on cylinder 3 and the car going into 'protection' mode (EPC). I am looking to replace all spark plugs this weekend. Also, do you have to clear codes after removing the SC for any reason?

I have the very slow coolant leak, and cylinder 3 misfires, too. However, my EPC never comes in at startup. Mine comes on only at full throttle at 7k+ rpm. I am guessing it is the IC. It seems like 3 is the one that usually fails first. Since this is the one nearest the passenger side firewall, I wonder if it has anything to do with being further away from the return line T ( as it is closer to the driver’s side, instead of centered).


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[whiped]

https://i.imgur.com/z7DQgNx.jpg

I had 6 fail after 3 failed. I think the back side of the cores are just structurally weaker.

This is what happens if you do pulls with blown cores. RIP.

[Loe]

ha! nice! but yeah they appear to be weaker at the ends

[brs2c]

Is there a certain spot on the end where they typically fail, or is it a new and exciting spot every time? If is is the same spot, might there be a way to just JB weld the weak spot to reinforce it (I know it is a ghetto solution, but repeatedly paying $225 is for the birds)?

[AdamInKC]

ha! nice! but yeah they appear to be weaker at the ends

Is there anything visually wrong with a bad core? Assuming the only way to test is by pressurizing the core and looking for leaks.

[whiped]

I'm not sure exactly where it bursts but I don't think I'd be easy to fix.

I sent one of my bad cores to Tyrolsport. Perhaps they will look at it and see where the weak point is.

[AdamInKC]

I ended up getting all parts at VWPartHub.com. Prices seemed pretty good.
Part Number Part Name Price Quantity Total
06E-145-621-R Cooler Assembly $176.00 2 $352.00
06E-145-723-E Cooler Assembly Seal $21.60 2 $43.20
079-129-717-D Manifold Gasket $3.47 6 $20.82
06E-103-213 Vent $3.20 1 $3.20
06E-121-119-D Washer $2.12 4 $8.48
N10451409 Bolt $0.60 12 $7.20

[brs2c]

I ended up getting all parts at VWPartHub.com. Prices seemed pretty good.
Part Number Part Name Price Quantity Total
06E-145-621-R Cooler Assembly $176.00 2 $352.00
06E-145-723-E Cooler Assembly Seal $21.60 2 $43.20
079-129-717-D Manifold Gasket $3.47 6 $20.82
06E-103-213 Vent $3.20 1 $3.20
06E-121-119-D Washer $2.12 4 $8.48
N10451409 Bolt $0.60 12 $7.20

Those are great prices. But, the problem with them, and a lot of the other sites I saw when searcing is the shipping. They want $38 for shipping on one IC and $55 shipping for 2. So, getting multiple units helps to divide the high shipping cost, but it still increase it with each item you add. This site has the IC's it for $192 https://www.audiusaparts.com/, but the shipping is showing free to me.

[mjr034]

I had cylinder 3 misfiring on WOT pretty consistently for a couple months..

Replaced all the plugs a few weeks ago (old ones looked burned and ashed tips when i pulled them.
Put in fresh NGK stocks gapped to .026. Seemed to take care of the WOT issue.
Noticed rough startups but was quickly evening out for a few days now - then tonight threw a CEL.

Checked the codes and logged for a bit.
1. On startup cylinder 3 misfiring about 10-30 times and then evens out.
2. WOT misfires once or so randomly on various cylindersbefore upshift.

Was going to swap coilpacks tomorrow to double confirm. Any suggestions? but seems to be everyone's similar issue here.
Did just get seasonably cold up here, and went to DP and Bigger Cooler up front back in the summer.

[cjw]

I'm having really small coolant loss. I rarely beat on the car. Just log misfires and that's it? Do you log at WOT or does it matter?

If I hit up the dealer for repair, get them both done?

[evil35r]

Is your system divorced?

[ModItNow]

I'm having really small coolant loss. I rarely beat on the car. Just log misfires and that's it? Do you log at WOT or does it matter?

If I hit up the dealer for repair, get them both done?Pull the spark plug on cyl 3 and look at it. This is what mine looked like and when the supercharger got pulled it was a mess underneath there and cost me a lot of money to get it all cleaned up.
Get it repaired asap, the other intercooler is probably fine but if you have high mileage I would buy switch that one out as well9528895289

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[cjw]

Not divorced. Car has never really been flogged beyond a gear or two. I have about 50k miles on it.

Cyl 3 is passenger firewall?

[evil35r]

Yes passenger firewall. If you’re losing coolant though and not divorced there is a myriad of other things that it could be leaking from though. If you were divorced it’s more clear cut

- - - Updated - - -

Do you have a clearer pic of the plug?

[whiped]

Pull the spark plug on cyl 3 and look at it. This is what mine looked like and when the supercharger got pulled it was a mess underneath there and cost me a lot of money to get it all cleaned up.
Get it repaired asap, the other intercooler is probably fine but if you have high mileage I would buy switch that one out as well9528895289

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That looks tasty!

Here is what mine looked like when my IC went:
https://i.imgur.com/JW3uzqi.jpg

You could also see some build up on the plug:
https://i.imgur.com/NoMbG6i.jpg

I think mine faired better than yours because of the constant meth washing lol.

[evil35r]

Your plug looked pretty normal Geoff?

[ModItNow]

Yeah I didn't realize the issue was there for a while and then it too late. Nasty town.

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[whiped]

Your plug looked pretty normal Geoff?

Two of the 3 prongs were coolant fouled. (The white stuff on the tips)

[evil35r]

So how do these look then? Cyl 6 is in the socket cyl 3 isn’t. Have the smallest coolant loss if any. Also running e30 and starbrite https://i.ibb.co/q5n3216/CB4-DE63-E-823-D-4-A6-F-A398-BD5-D36-B235-FB.jpg (https://ibb.co/sHPdX37) https://i.ibb.co/HCZPQQs/42-EC015-D-0-F51-4-B99-9-B28-6-C27-D2-BC7-B9-C.jpg (https://ibb.co/FXpYttM) https://i.ibb.co/cNtsN6M/D126-FF2-A-1-B6-B-4-A2-F-BB6-E-995219-CCE2-FB.jpg (https://ibb.co/NLpGL9Q) https://i.ibb.co/3TBKQzW/89198-D2-D-F8-A2-45-B8-ACD6-81-AEF6-E5-E7-F8.jpg (https://ibb.co/6ygQLBb)

[whiped]

Do they all look like that? Sometimes fuel additives will leave deposits on your plugs...

If they all look the same I wouldn't worry too much.

[evil35r]

Yea all look the same gonna pull again this weekend to re check

[ModItNow]

So how do these look then? Cyl 6 is in the socket cyl 3 isn’t. Have the smallest coolant loss if any. Also running e30 and starbrite https://i.ibb.co/q5n3216/CB4-DE63-E-823-D-4-A6-F-A398-BD5-D36-B235-FB.jpg (https://ibb.co/sHPdX37) https://i.ibb.co/HCZPQQs/42-EC015-D-0-F51-4-B99-9-B28-6-C27-D2-BC7-B9-C.jpg (https://ibb.co/FXpYttM) https://i.ibb.co/cNtsN6M/D126-FF2-A-1-B6-B-4-A2-F-BB6-E-995219-CCE2-FB.jpg (https://ibb.co/NLpGL9Q) https://i.ibb.co/3TBKQzW/89198-D2-D-F8-A2-45-B8-ACD6-81-AEF6-E5-E7-F8.jpg (https://ibb.co/6ygQLBb)That second pic doesn't look too good. I would swap them out soon. Mine was just cyl 3 and you could tell fluid leaked on it.

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[evil35r]

That one is cyl 6. I plan to swap them out when I install the ported sc

[ModItNow]

That one is cyl 6. I plan to swap them out when I install the ported scWhat plugs are you going to run, oem or something else? I have NGK Iridiums on that seem to be working good but was thinking of trying Brisk.

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[evil35r]

Same thing brisk plugs...

[Johnson]

Got around to leak testing my old intercooler. It was leaking in cylinder 3. Looks like it's from the end tank area. Revision F.

https://youtu.be/nXdvRz3ogCo

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[scalbert]

Pull the spark plug on cyl 3 and look at it. This is what mine looked like and when the supercharger got pulled it was a mess underneath there and cost me a lot of money to get it all cleaned up.
Get it repaired asap, the other intercooler is probably fine but if you have high mileage I would buy switch that one out as well9528895289



Just curious, did you pull the SC and lower intake manifold to take the picture? Or was it the shop that took the picture? I ask as the cleaning of that port was not hard. I did mi e in 30 minutes with picks, shop vac and air. Granted, this was with the SC off as I was replacing the intercoolers anyway as well as the PCV assembly.

[ModItNow]

Just curious, did you pull the SC and lower intake manifold to take the picture? Or was it the shop that took the picture? I ask as the cleaning of that port was not hard. I did mi e in 30 minutes with picks, shop vac and air. Granted, this was with the SC off as I was replacing the intercoolers anyway as well as the PCV assembly.Yes it was a picture the shop sent me. They ended up taking the intake manifold off to do a full carbon clean, not sure if it was removed already when this pic was taken though.

If it wasn't for all the carbon they would have just been able to clean out that one port and reinstall the charger but my injector o rings looked like they needed replacing and all my injectors had carbon build up on them. I was not expecting all that at 46k miles, I guess I've really beaten on my car lol

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[scalbert]

Yes it was a picture the shop sent me. They ended up taking the intake manifold off to do a full carbon clean, not sure if it was removed already when this pic was taken though.

If it wasn't for all the carbon they would have just been able to clean out that one port and reinstall the charger but my injector o rings looked like they needed replacing and all my injectors had carbon build up on them. I was not expecting all that at 46k miles, I guess I've really beaten on my car lol

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Thanks. Just wanted to be sure. The lower intake manifold was removed in that picture as you can see the full injector.

[ModItNow]

Thanks. Just wanted to be sure. The lower intake manifold was removed in that picture as you can see the full injector.At this point I really need to find the time to start learning to work on the car myself!

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[cjw]

I pulled all my plugs. They all looked the same. I compared them to my old 35k mile stock plugs and they look the same.

Running heat range 8 NGK Iridium plugs. Pretty sure that's the stock range.

These have about 15k dual pulley miles running 94 octane only. The gap grew a bit, so I shrunk them back to about 0.026".


https://lh3.googleusercontent.com/oRa2QBC2e37HTYDC5jWDD3V0UvTCXXliLFzmPZRnzAd7ag_v-V-J1PUyrn7BrxpJPgY0PVzrLKlCMjyROp1SZD_anp8Fk1GT0XFHw 3olJIgYsP2unSW0hYfC3Y0poQ7ha-sGE0p45BlEEtszjAYj1bPlomm41z1QBEwOknkRBIDhRkYI0pRV mEWQOObfnfyRjtCcvdm_H4H87QLV6hq4-9yHrZnNxXmwALj_GnWKZCs5f0dfnMLzCscF2SrfUCgkw0qp-mX-LD22x52zoI-SkZ63ihvZVqccIUJCNU6Js7WYB6f83GU3j7rpIWqPZZHz0TtbA XnuxSmZIu_iOtZQKWDzXhPDOxtMnUUm-kcd543AVYadSRVD3dcb3NuVCHuLcB3bwRgaMYzNjizf9OuJYOu 7G4c_DYoTH5qSKMNZufRMWOLfM-rywdzrClgWnS8njQO5yB4oaZZJzowzYyEjIKjmVlY18V9kx4UW ht3KjzTRTjQ1Mz1PZ-VE6YmybA3oeW2wS76JVH8qQw6qsWPz-pepJT2vuJpu26KPDu6qJIU7QHTVcclGWxCjOcApv1iH4CuimN9 yQ_9frjs2cH275gM-EGCCopIAwKYcc3LTxOtI_fM6qVM5PQji624lbSZzjIm41UApZ-w4LPFS1XGW0iXDRg=w1374-h1830-no-tmp.jpg

[Morritse]

At this point I really need to find the time to start learning to work on the car myself!

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Changing an intercooler really isn't too hard. It should only take you a few hours. Just make sure you mark all the vacuum lines

[pdqgp]

OK so I started the car after letting it sit for 3 days over the weekend and it started up flawlessly with no roughness whatsoever. I'm going to replace the spark plugs because I was going to before anyways so we can eliminate that. But if that doesn't help, any other suggestions?

if you have a scope/camera you can look into each one and look for a clean spot. your symptoms sound like one of the baby heat ex changers is dripping coolant. if so you'll see a fouled plug and a clean spot.

[pdqgp]

Pull the spark plug on cyl 3 and look at it. This is what mine looked like and when the supercharger got pulled it was a mess underneath there and cost me a lot of money to get it all cleaned up.
Get it repaired asap, the other intercooler is probably fine but if you have high mileage I would buy switch that one out as well9528895289

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^^ Same area that failed on mine.

[scalbert]

^^ Same area that failed on mine.

Seems to be the same spot for nearly all.

[MSq5]

Just replaced plugs with NGK Laser Platinum stock heat range and gapped to .026". I did this because of repeated misfire on cylinder 3 and one misfire on cylinder 6 that were causing a misfire code for the respective cylinders and a cylinder shut down occurring under full throttle heavy load conditions. P0303, P0306, and cylinder disable, P130A.

This was typically spoiling my recent attempted Dragy runs! If I shut the engine off and restart it the engine recovers but leaves the above codes on VCDS scan. Either cylinder 3 or cylinder 6, one time both. I have not scanned individual cylinder misfire frequency. The engine seemed to run fine as long as I did not try full throttle acceleration.

Mileage is 36,000. Not sure this is due to saddle IC core leaks or just time to replace the plugs. I hope it is just plugs. Per signature below I'm EPL stage 2 single pulley 2.8:1 ratio (relatively low in comparison to most here) and still on stock cooling but running 70% water, 30% coolant, and water wetter.

Given that IC leaks happen on completely stock cars, I'm bracing for the worst and hoping its just the plugs. Should know pretty soon. Right now, all symptoms have disappeared.

[Morritse]

Just replaced plugs with NGK Laser Platinum stock heat range and gapped to .026". I did this because of repeated misfire on cylinder 3 and one misfire on cylinder 6 that were causing a misfire code for the respective cylinders and a cylinder shut down occurring under full throttle heavy load conditions. P0303, P0306, and cylinder disable, P130A.

This was typically spoiling my recent attempted Dragy runs! If I shut the engine off and restart it the engine recovers but leaves the above codes on VCDS scan. Either cylinder 3 or cylinder 6, one time both. I have not scanned individual cylinder misfire frequency. The engine seemed to run fine as long as I did not try full throttle acceleration.

Mileage is 36,000. Not sure this is due to saddle IC core leaks or just time to replace the plugs. I hope it is just plugs. Per signature below I'm EPL stage 2 single pulley 2.8:1 ratio (relatively low in comparison to most here) and still on stock cooling but running 70% water, 30% coolant, and water wetter.

Given that IC leaks happen on completely stock cars, I'm bracing for the worst and hoping its just the plugs. Should know pretty soon. Right now, all symptoms have disappeared.

From my experience, any leak bad enough to cause cylinder disabling will cause a noticeable loss in coolant.

[MSq5]

From my experience, any leak bad enough to cause cylinder disabling will cause a noticeable loss in coolant.

Good to know. Coolant level is normal and stable . . . so far.

[Gkit19986]

So I’m now experiencing the same symptoms most of you guys been . Cylinder 3 and 6 have been misfiring and coolant loss is extreme.

I was planing to install my APR CPS and change plugs next week, but it seems i have a bigger problem on my hands.

I’m literally not mechanically inclined but can follow directions well. Replacing the intercoolers, is it a difficult job ?

[Morritse]

So I’m now experiencing the same symptoms most of you guys been . Cylinder 3 and 6 have been misfiring and coolant loss is extreme.

I was planing to install my APR CPS and change plugs next week, but it seems i have a bigger problem on my hands.

I’m literally not mechanically inclined but can follow directions well. Replacing the intercoolers, is it a difficult job ?

It really isn't. The hardest part is probably taking the belt off if you don't have a tool and making sure you connect all the vacuum tubes and wires correctly.

[Gkit19986]

I ended up getting all parts at VWPartHub.com. Prices seemed pretty good.
Part Number Part Name Price Quantity Total
06E-145-621-R Cooler Assembly $176.00 2 $352.00
06E-145-723-E Cooler Assembly Seal $21.60 2 $43.20
079-129-717-D Manifold Gasket $3.47 6 $20.82
06E-103-213 Vent $3.20 1 $3.20
06E-121-119-D Washer $2.12 4 $8.48
N10451409 Bolt $0.60 12 $7.20

Hey guys, its time for me to replace my intercooler.
Some of these part #s aren’t fitting my car. I got a 2014 s4 b8.5.
It’s odd because the application states it fits a 2016 b8.5 s4 but isn’t compatible with a 2014 s4. I just need to confirm before purchasing.

[street2gen]

Well it seems i had this happen but mine seems a bit different then the normal. Only misfires on cyl 1, EPC on WOT runs and what im assuming is cyl shut down, car was running very very poor until resetting epc. and some coolant loss. blowing some white smoke at wot. Parked it pulled the charger and threw them in a bucket like video above and some bubbles around the top right and top left corners on the bleeder side. Not really much telling in the valves just look like carbon buildup but no coolant mess, no problems with cyl 3 or 6 either. Is it possible that i just caught it before it became a real problem?
One weird thing my brother is going through the same and we both switched from FR5DTC Plugs back to stock then like same day noticed white smoke on WOT.
I have some weird timing hesitation which was the reason for switching plugs but otherwise no smoke with FR5s.
I def think switching back to the stock plugs is what kicked things off, but would anybody have some assumptions as to why?

[street2gen]

Also it seems this is where they leak.
122434

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[ModItNow]

Well it seems i had this happen but mine seems a bit different then the normal. Only misfires on cyl 1, EPC on WOT runs and what im assuming is cyl shut down, car was running very very poor until resetting epc. and some coolant loss. blowing some white smoke at wot. Parked it pulled the charger and threw them in a bucket like video above and some bubbles around the top right and top left corners on the bleeder side. Not really much telling in the valves just look like carbon buildup but no coolant mess, no problems with cyl 3 or 6 either. Is it possible that i just caught it before it became a real problem?
One weird thing my brother is going through the same and we both switched from FR5DTC Plugs back to stock then like same day noticed white smoke on WOT.
I have some weird timing hesitation which was the reason for switching plugs but otherwise no smoke with FR5s.
I def think switching back to the stock plugs is what kicked things off, but would anybody have some assumptions as to why?Sounds like your cats are failing

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[ModItNow]

Also it seems this is where they leak.
122434

Sent from my Pixel XL using Audizine mobile app (http://r.tapatalk.com/byo?rid=87676)Yup exactly, I tested my first failed one. Second one coming off for replacement soon 🤦

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[Morritse]

Sounds like your cats are failing

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Yup, could also be PCV if you have coolant loss

[street2gen]

Sounds like your cats are failing

Sent from my SM-G965U using Audizine mobile app (http://r.tapatalk.com/byo?rid=87676)Cats would probably show signs with the coolant going through though right? Because they are showing. 122538

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[street2gen]

Swapped to a 40k charger still same problems, not showing any pcv symptoms no coolant on oil cap oil or breather tubes.
Guess im leaning towards cats.


4 Faults Found:
6352 - Cylinder 3
P0303 00 [101] - Misfire Detected
Not Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 165048 km
Date: 2019.05.24
Time: 22:28:08

Engine speed: 6091.00 /min
Normed load value: 100.0 %
Vehicle speed: 122 km/h
Coolant temperature: 91 °C
Intake air temperature: 21 °C
Ambient air pressure: 970 mbar
Voltage terminal 30: 13.710 V
Unlearning counter according OBD: 40
Engine speed: actual: 6144 /min
MAF_ENVD: 1329.08232 mg/stroke
Coolant temperature (unfiltered): 91.5 °C
Engine: operating status: PL
T_AST_ENVD: 462.60 s
Vehicle speed: actual: 122 km/h

6170 - Signal Line for Fuel Pump Electronics
P3089 00 [032] - Electrical Malfunction
Intermittent - Not Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 2
Mileage: 165044 km
Date: 2019.05.24
Time: 21:37:07

Engine speed: 0.00 /min
Normed load value: 0.0 %
Vehicle speed: 0 km/h
Coolant temperature: 18 °C
Intake air temperature: 21 °C
Ambient air pressure: 970 mbar
Voltage terminal 30: 11.577 V
Unlearning counter according OBD: 39
Engine speed: actual: 0 /min
MAF_ENVD: 0.00000 mg/stroke
Coolant temperature (unfiltered): 18.8 °C
Engine: operating status: ES
FUP_EFP_ENVD: 681.914 hPa
Vehicle speed: actual: 0 km/h

6487 - Engine Off Timer Performance
P150A 00 [032] - -
Intermittent - Not Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 165044 km
Date: 2019.05.24
Time: 21:43:44

Engine speed: 0.00 /min
Normed load value: 0.0 %
Vehicle speed: 0 km/h
Coolant temperature: 18 °C
Intake air temperature: 20 °C
Ambient air pressure: 970 mbar
Voltage terminal 30: 8.835 V
Unlearning counter according OBD: 39
Engine speed: actual: 0 /min
MAF_ENVD: 0.00000 mg/stroke
Coolant temperature (unfiltered): 18.8 °C
Engine: operating status: ES
Battery voltage: 8.937500 V
Vehicle speed: actual: 0 km/h

7948 - Cylinder Disabling
P130A 00 [101] - -
Not Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 165048 km
Date: 2019.05.24
Time: 22:28:09

Engine speed: 6189.00 /min
Normed load value: 82.0 %
Vehicle speed: 123 km/h
Coolant temperature: 91 °C
Intake air temperature: 21 °C
Ambient air pressure: 970 mbar
Voltage terminal 30: 13.710 V
Unlearning counter according OBD: 40
Engine speed: actual: 6176 /min
MAF_ENVD: 1361.76467 mg/stroke
Coolant temperature (unfiltered): 91.5 °C
Engine: operating status: PL
T_AST_ENVD: 462.60 s
Vehicle speed: actual: 123 km/h

[mjr034]

This is a pain. Had my bank 1 intercooler blow in the fall and replaced it only to blow the bank 2 one by February. Finally had them both replaced and cleaned up my issues. Both blew holes right in the side near the gasket seals. They seemed to be my weak point whenever I upgraded cooling and went to dual pulley.


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[street2gen]

What a week 123072123073123074

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[Johnson]

Street2gen, did you have any symptoms that pointed you to cats?

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[street2gen]

Street2gen, did you have any symptoms that pointed you to cats?

Sent from my SM-G920V using TapatalkYeah I started seeing the 02 sensor code as well and all the normal ones like exhaust note change loss of power epc light so on.
I'm not sure if my leaking charger cores did it or my plugged cats did my cores in.

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[04v8s4]

Are most of you that are seeing these IC failures also running some kind of modified cooling system?

I wonder if the combination of higher boost (higher temps) and upgraded cooling systems (lower temps) is causing a larger temp differential across the IC and causing material fatigue?

Thoughts?

[bhvrdr]

Are most of you that are seeing these IC failures also running some kind of modified cooling system?

I wonder if the combination of higher boost (higher temps) and upgraded cooling systems (lower temps) is causing a larger temp differential across the IC and causing material fatigue?

Thoughts?

It must be a bit of a crapshoot. Ive had three 3.0t cars (4 actally but one was only stage 1) and had both divorced and non divorced cooling systems and never had a leak in any. Go figure. Now i realize I just jinxed myself lol

[whiped]

The newer 10-row ICs are more fragile than the older 9-row ones.

With that said, the best bet to prevent your ICs from rupturing is to drive your car a bit or leave it on after driving it hard.

My theory is that the ICs blow when the car is off after running hard. The fluid gets too hot and has nowhere to expand thus causing pressure to increase and rupture the ICs.

By keeping the car on or doing the pump mod + unlocking the car periodically you keep the pump running and avoid any "hot spots".

You can also relieve pressure in the whole system if you are divorced by opening the res. (It shouldn't be under much pressure)

YMMV, I've blown 3 10-row cores and 0 9-rows.

[street2gen]

Im guessing my cats failing would also add heat and pressure on the system?

[durpydurps]

So I'm having coolant loss myself. Also just got a misfire code on cyl 3 but no epc light, could kinda hear it in the exhaust but car was running fine. My system is divorced and the leak is coming from the SC loop. Engine coolant loop is perfect, level in the coolant tank hasn't moved ever. SC reservoir/expansion tank needs to be topped off daily with at least an oz or two of coolant.
Sounding like leaky intercooler on passenger side no? Pulled the plug on cyl 3 and it seemed good to me. I do see a little bit of white residue, burnt coolant? About 10k on these plugs with stage 2 DP.

Edit: i do smell a little coolant coming from the small expansion tank area, its right behind the driverside headlamp. But i see no leaks at all! Not one drip. Tightened all the clamps.

[mjr034]

The newer 10-row ICs are more fragile than the older 9-row ones.

With that said, the best bet to prevent your ICs from rupturing is to drive your car a bit or leave it on after driving it hard.

My theory is that the ICs blow when the car is off after running hard. The fluid gets too hot and has nowhere to expand thus causing pressure to increase and rupture the ICs.

By keeping the car on or doing the pump mod + unlocking the car periodically you keep the pump running and avoid any "hot spots".

You can also relieve pressure in the whole system if you are divorced by opening the res. (It shouldn't be under much pressure)

YMMV, I've blown 3 10-row cores and 0 9-rows.

Thanks for the Tips - about how long are you running idle after getting it hot?

[Big_Joe]

ive been losing lots of coolant lately but I dont have any misfires and theres no signs of leaking anywhere, havent pulled the SC yet to check the PCV, ive been driving the car pretty hard. has unitronic stage 2. I had to fill the bottle pretty much up from about 2" from the bottom of the reservoir after two weeks. coolant temp is dead on at 90C no matter how i drive. the ground electrode on the spark plug is white on cylinder 1 & 2 (only ones i pulled so far). last week i noticed it gargling when shutting it off and then the level went from full to min. i started the car up and ran it and then shut it off and it filled back up to the full mark. just find it weird to be losing so much coolant and no real issues or CELs

[ModItNow]

ive been losing lots of coolant lately but I dont have any misfires and theres no signs of leaking anywhere, havent pulled the SC yet to check the PCV, ive been driving the car pretty hard. has unitronic stage 2. I had to fill the bottle pretty much up from about 2" from the bottom of the reservoir after two weeks. coolant temp is dead on at 90C no matter how i drive. the ground electrode on the spark plug is white on cylinder 1 & 2 (only ones i pulled so far). last week i noticed it gargling when shutting it off and then the level went from full to min. i started the car up and ran it and then shut it off and it filled back up to the full mark. just find it weird to be losing so much coolant and no real issues or CELsIf it's your intercooler it's going to be leaking on cyl 3 plug. Pull it and compare to the others

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[Big_Joe]

I pulled the insulation padding out and looked around the PCV and there seems to be some dried up pink coolant and a few wet spots after its been sitting for a day, so I imagine its the PCV, most threads ive read that have leaking intercoolers seem to be having misfires. I have no misfires at idle, driving or WOT. So I doubt that the intercoolers are leaking. Ill have to remove the SC and drain the oil to confirm.

[bhvrdr]

Ive probably been struck.

My system is divorced and i noticed the supercharger loop is losing coolant. I dont see and obvious leaks although i suppose there could be a tiny one somewhere but nothing thats puddling.

I get zero misfires, zero codes, zero driveability issues.

Interestingly when i installed the ported charger i used a newer 10 row ic for the first time.

Anyways just wondering if folks had leaky intercolers with zero codes or misfires???

One thing that's interesting and maybe you guys can tell me if this is a less talked about sogn but when I went to undo the cap for my intercooling reservoir I had to use a pipe wrench to get the dam thing off there was so much suction. Thats not normal for my car at all.

[street2gen]

Ive probably been struck.

My system is divorced and i noticed the supercharger loop is losing coolant. I dont see and obvious leaks although i suppose there could be a tiny one somewhere but nothing thats puddling.

I get zero misfires, zero codes, zero driveability issues.

Interestingly when i installed the ported charger i used a newer 10 row ic for the first time.

Anyways just wondering if folks had leaky intercolers with zero codes or misfires???

One thing that's interesting and maybe you guys can tell me if this is a less talked about sogn but when I went to undo the cap for my intercooling reservoir I had to use a pipe wrench to get the dam thing off there was so much suction. Thats not normal for my car at all.

I dont have a divorced system, but that is really weird that you still have a vacuum on it. I would think that a negative or even positive pressure would dissipate after time with a leak.

[bhvrdr]

I dont have a divorced system, but that is really weird that you still have a vacuum on it. I would think that a negative or even positive pressure would dissipate after time with a leak.

Now im perplexed. I've pulled both the supercharger cores and I cannot find a leak anywhere in them.

When I filled them up with water and put pressure no water comes out anywhere and when I just put air pressure I can't hear any hissing.

All the intake valves look perfectly fine and I was never getting any misfires in any cylinder. But I cannot figure out where the heck the coolant is going.

[killer_s4]

Are you sure it wasn't just an air bubble in the system that finally burped itself?

[bhvrdr]

Are you sure it wasn't just an air bubble in the system that finally burped itself?

I may have made myself so darn paranoid that maybe it was indeed needing to burp and then I would fill it up all the way to the top when the engine was warm and come to think of it I'm checking it in the morning when the engine is cool and I see the level down slightly and I may be just mistaking it for different levels when the engine is warm vs cool. Boy this is a pain in the butt because I have everything apart haha and i dont want to put it together until i know grr

Anyone know how much pressure I need to put through these cores to be able to tell if there is a leak or not

. I'm basically using my mouth on one and and sealing the other hole and either filling them up with air or water and blowing as hard as I can.

[killer_s4]

stick the hose in one side and youll see if it leaks. doesn't take a lot of pressure. I avoid all these damn threads because ill get paranoid/jinx myself. same shit with the cats.

[bhvrdr]

stick the hose in one side and youll see if it leaks. doesn't take a lot of pressure. I avoid all these damn threads because ill get paranoid/jinx myself. same shit with the cats.

Haha the same thing clearly happens to me. I'm pretty sure I just pulled the supercharger for nothing. Oh well ill look around in here and see if anything needs to be cleaned ha

[killer_s4]

If I was closer to you id go help if that makes it any better lol. Luckily the sc isn't that big of a pain.

[JACKAL]

I may have made myself so darn paranoid that maybe it was indeed needing to burp and then I would fill it up all the way to the top when the engine was warm and come to think of it I'm checking it in the morning when the engine is cool and I see the level down slightly and I may be just mistaking it for different levels when the engine is warm vs cool. Boy this is a pain in the butt because I have everything apart haha and i dont want to put it together until i know grr

Anyone know how much pressure I need to put through these cores to be able to tell if there is a leak or not

. I'm basically using my mouth on one and and sealing the other hole and either filling them up with air or water and blowing as hard as I can.

I completely understand developing paranoia because of reading threads on here and I do not want to add to yours, but just to share something that may be of interest or use...

I recently discovered that the 6 greenish gaskets(079129717D) which seal the S/C to the intake manifolds do relax over time and, at least in my case, should have been replaced when I installed my ported S/C because I developed a 'high idle intake air' fault code. I was driving myself nuts trying to find out where the leak was and the only reason I ever figured it out was because when I had my intercooler leak, I inspected the bottom of the blower very carefully and found evidence of dried coolant on the S/C belly by the number 6 cylinder. The coolant pattern appeared to have been sprayed (as would happen when some of the pressurized air was leaking out and splattering the coolant that was pooling in the S/C valley by the PCV). I also noticed that my #6 spark plug was significantly darker than the others indicating a rich condition since I was loosing a small amount of air because of that stupid gasket.

Anyway, I really don't want to add to anyone's paranoia as I know many have removed and replaced the S/C without needing new gaskets. I'm just throwing this out there as an FYI in case it can save someone else the frustration I endured. Also these gaskets are only a few bucks online but since I discovered it late and almost by accident I didn't have time to wait around for shipping so I ended up dropping almost $60 at the stealership.

[killer_s4]

You’re supposed to change out those gaskets every time you remove the supercharger. They’re too cheap to skip out on for peace of mind

[street2gen]

I used compressed air but didn't make a seal tight fitting, as to just blow them out by testing. That being said I had a tiny bit of air bubbles coming out each nothing crazy so I'm guessing blow them with your mouth probably not going to happen..... You have a bike pump and a helper? I'll bet that could work pretty safely actually.

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[bhvrdr]

I used compressed air but didn't make a seal tight fitting, as to just blow them out by testing. That being said I had a tiny bit of air bubbles coming out each nothing crazy so I'm guessing blow them with your mouth probably not going to happen..... You have a bike pump and a helper? I'll bet that could work pretty safely actually.

Sent from my Pixel 3 XL using Audizine mobile app (http://r.tapatalk.com/byo?rid=87676)Great idea. I was able to spike about 30PSI and still no bubbleshttps://uploads.tapatalk-cdn.com/20190708/ba5ecd3c3fb9b1e7a69a802f2dd5c3b0.jpg

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[Morritse]

You guys are making this complicated. Just cover one of the holes with your finger, put ur mouth over the other one and give it a good succ. It was easy to hear air coming in the one with a leak.

Tasted a bit bad but it was super easy to tell the difference on 4 cores I tried it with

[bhvrdr]

That's the 1st thing I did. I did it with pure air and then I did it filled with water and then I decided to dunk it in water and blow air and then I said screw it and rigged up the pump. I'm going to say that they're not leaking

[street2gen]

You guys are making this complicated. Just cover one of the holes with your finger, put ur mouth over the other one and give it a good succ. It was easy to hear air coming in the one with a leak.

Tasted a bit bad but it was super easy to tell the difference on 4 cores I tried it withLol..... The little leaks that I had on mine you'd blow a nut trying to suck fluid through.

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[killer_s4]

Maybe Morritse has a hidden talent

[Morritse]

Maybe Morritse has a hidden talent

( ͡° ͜ʖ ͡°)

[bhvrdr]

Just as an FYI I found these inter coolers on eBay and it was crazy that they shipped from Great Britain in literally 2 days. They were sent fedex and arrived the 2nd day after I ordered them. $115 all in[


https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.co.uk%2Fulk%2Fitm%2F 302448825150

IMG]https://uploads.tapatalk-cdn.com/20190709/2dbcfc06a6d71d8ab9cf038163499559.jpg[/IMG]https://uploads.tapatalk-cdn.com/20190709/c0e0b64590834c562f07b94a5b6744c9.jpg

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[JACKAL]

Just as an FYI I found these inter coolers on eBay and it was crazy that they shipped from Great Britain in literally 2 days. They were sent fedex and arrived the 2nd day after I ordered them. $115 all inhttps://uploads.tapatalk-cdn.com/20190709/2dbcfc06a6d71d8ab9cf038163499559.jpghttps://uploads.tapatalk-cdn.com/20190709/c0e0b64590834c562f07b94a5b6744c9.jpg

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Wow man, that’s impressive. I paid almost $400 for two intercoolers via eBay and it took almost 2 weeks for arrival. Nice find.


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[bhvrdr]

If it becomes a consensus that the newer 9 row of tube cores are failing more frequently than the older 8 tube cores AND the failure points seem to be at the rear/endtanks i can see why. It looks like adding the 9th row probably makes them more efficient but i can see more pressure building as well...https://uploads.tapatalk-cdn.com/20190710/983fbda7ac3ce479d45bbdda0d77cacf.jpghttps://uploads.tapatalk-cdn.com/20190710/a072bec1e8605464209da4db8be3e365.jpghttps://uploads.tapatalk-cdn.com/20190710/2763b44db64dc6aa88e004fc48c7ce17.jpghttps://uploads.tapatalk-cdn.com/20190710/64f9f0da6b3dc2a7a8f2d799d120bccb.jpghttps://uploads.tapatalk-cdn.com/20190710/9138bc54e47c0234a691584ae0b93a92.jpg

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[Shane Horning]

If it becomes a consensus that the newer 9 row of tube cores are failing more frequently than the older 8 tube cores AND the failure points seem to be at the rear/endtanks i can see why. It looks like adding the 9th row probably makes them more efficient but i can see more pressure building as well...https://uploads.tapatalk-cdn.com/20190710/983fbda7ac3ce479d45bbdda0d77cacf.jpghttps://uploads.tapatalk-cdn.com/20190710/a072bec1e8605464209da4db8be3e365.jpghttps://uploads.tapatalk-cdn.com/20190710/2763b44db64dc6aa88e004fc48c7ce17.jpghttps://uploads.tapatalk-cdn.com/20190710/64f9f0da6b3dc2a7a8f2d799d120bccb.jpghttps://uploads.tapatalk-cdn.com/20190710/9138bc54e47c0234a691584ae0b93a92.jpg

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https://uploads.tapatalk-cdn.com/20190710/65e8e225705084f74e927d6512b9930b.jpgWere yours leaking or did you swap them out to try the 9 tube core? Also are the ones you got the same thing as ecs sells? Big price difference

[bhvrdr]

Were yours leaking or did you swap them out to try the 9 tube core? Also are the ones you got the same thing as ecs sells? Big price difference

Turns out mine were not leaking. I bought some as backups. I have a few superchargers here also so I have here and E revision (8 tube), an F revision ( 9 tube) and now the new Behr/Mahle from the UK. The new BEHR / MAHLE is identical visually to the F revision unit that is also a BEHR unit. Same manufacturer and even same number of "W97940002" on both the F and BEHR. Both made in germany. I'd guess they're the same or perhaps its the same as the latest R revision. Not sure as I dont have one of those.

Mike
https://uploads.tapatalk-cdn.com/20190710/8609db099526f344d2b57c1a0c8a47fd.jpghttps://uploads.tapatalk-cdn.com/20190710/1766b4c31ba12a46f53d2234091045d0.jpg

[MSq5]

Turns out mine were not leaking. I bought some as backups. I have a few superchargers here also so I have here and E revision (8 tube), an F revision ( 9 tube) and now the new Behr/Mahle from the UK. The new BEHR / MAHLE is identical visually to the F revision unit that is also a BEHR unit. Same manufacturer and even same number of "W97940002" on both the F and BEHR. Both made in germany. I'd guess they're the same or perhaps its the same as the latest R revision. Not sure as I dont have one of those.

Mike
https://uploads.tapatalk-cdn.com/20190710/8609db099526f344d2b57c1a0c8a47fd.jpghttps://uploads.tapatalk-cdn.com/20190710/1766b4c31ba12a46f53d2234091045d0.jpg

Are you back up and running now? If you've completed the burping, bleeding, are you now holding coolant level? Hopefully, it was just air in the system. Your experience has been helpful to all of us, especially in identifying the differences in the older and new cores and why the new ones might be more efficient but more vulnerable. Thank you!

I wonder if there would be any interest in someone developing an aftermarket bolt on supercharger saddle intercooler system that has more capacity and also is more robust. One would think there are enough of these superchargers on various cars to justify such a product.

I also appreciate your information on how to locate reasonably priced replacement cores. I think I will go ahead and buy a pair from your eBay UK source in anticipation of the inevitable, now that I'm at 3.25 pulley ratio and running the Merc HX (undivorced at this point).

[Shane Horning]

Turns out mine were not leaking. I bought some as backups. I have a few superchargers here also so I have here and E revision (8 tube), an F revision ( 9 tube) and now the new Behr/Mahle from the UK. The new BEHR / MAHLE is identical visually to the F revision unit that is also a BEHR unit. Same manufacturer and even same number of "W97940002" on both the F and BEHR. Both made in germany. I'd guess they're the same or perhaps its the same as the latest R revision. Not sure as I dont have one of those.

Mike
https://uploads.tapatalk-cdn.com/20190710/8609db099526f344d2b57c1a0c8a47fd.jpghttps://uploads.tapatalk-cdn.com/20190710/1766b4c31ba12a46f53d2234091045d0.jpgThanks for the reply! I'd be interested in seeing if the new revision keeps iats any lower. Something I always struggle with above 70* weather. However I don't have cooling divorced or a reservoir just added a mercracing hx

[Allan691]

Pulled SC during T-Stat/H2O pump/PCV job and found this... Pretty sure I have an additional problem. I think wet and red and cruddy is non bene. Going to remove them and test, and then most likely going to order 2 using Mike’s link. Thanks Mike.
156212156213156214

Still have to remove intake runners and check valves.. And gonna pull plugs and check.. But how bad does it look to you guys..?

[Allan691]

..

Still have to remove intake runners and check valves.. And gonna pull plugs and check.. But how bad does it look to you guys..?

Pulled plugs this morning. Not happy about the process and results. I’ll be posting a new topic with several other concerns, but here are photos - in this order: cylinder 3 > 2 > 1 > 6 > 5 > 4.

156230156231156232156233156234156235

Observations:
1) All appear to be fouled - My commute is very short and relatively slow, so that *MAY* explain the carbon.
1A) Tip on #5 was the only one without carbon on it. White means coolant..? Or is white good and all the carbon around it bad..?
2) Oil on threads of cylinder 1.. VCG ? Torque for the VC bolts? Will cranking down help? PCV ? Getting to that in the next 2 days...
3) Removal was as rough as I’ve ever experienced (rachet vibrating during rotation) with only #4 backingout smoothly. I couldn’t find any Anti-Seize here in Italy when I changed my plugs so I went without. Regretting it. Damage done..? New plugs and Anti-Seize and move on..?

TIA for any help or opinions.
A

[pwrudmann]

I pulled my supercharger a few weeks ago to replace my leaking intercooler and am about to get my new parts in the mail. Does anyone know the torque specs for the 4 long throttle body bolts and the bolts that hold the intercooler to the supercharger? I can't find them anywhere.

[Waffles_s4]

Well, if the IC is indeed leaking u would get lots of misfires at idle. If not, why even take everything apart in the first place? Also u would see traces of coolant on the intake ports, the valves, and so on

If everything is nice and clean, it's not your SC, probably something else.

[dev1983]

Well, if the IC is indeed leaking u would get lots of misfires at idle. If not, why even take everything apart in the first place? Also u would see traces of coolant on the intake ports, the valves, and so on

If everything is nice and clean, it's not your SC, probably something else.

Good info, I didn't realize I would have misfires at idle too. I only have the epc light during WOT...however I changed out the cylinder 3 coil and marked the coolant levels. Ill drive it a week to see if there's any change.

[djn876]

You won't really get misfires at idle unless it is really bad, getting them under heavy throttle is more likely as the pump is running and pressurizing the system, causing more leakage, at ilde, it will be less and the engine is in a state that is more forgiving.

[Waffles_s4]

Good info, I didn't realize I would have misfires at idle too. I only have the epc light during WOT...however I changed out the cylinder 3 coil and marked the coolant levels. Ill drive it a week to see if there's any change.

Taking off the SC itself is easy, and once thats done u can just visually inspect the rest. No need to remove the SC cores to know that they are leaking. if they are leaking u WILL find coolant on the intake valves, and those orange intake flaps

[dev1983]

Taking off the SC itself is easy, and once thats done u can just visually inspect the rest. No need to remove the SC cores to know that they are leaking. if they are leaking u WILL find coolant on the intake valves, and those orange intake flaps

Thanks. I’ll check it out once I get the time to take off the supercharger.


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[dubgli]

Bumping this thread.

I'm about to divorce my coolant system. Maybe I will depending on what the community has learned.

Has there been any compelling evidence that divorcing can cause leaky intercoolers?

Any tips on divorcing to best avoid leaky intercoolers if they are related? Have a bleed air hole? Don't use too much water?

- dubgli

[NohNoh]

If you dig in the life beyond stage 2 thread you’ll see some info on how to create vent tube to relieve pressure. It’s one of the more recent ones so start from the back and work your way forward


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[dubgli]

If you dig in the life beyond stage 2 thread you’ll see some info on how to create vent tube to relieve pressure. It’s one of the more recent ones so start from the back and work your way forward


Sent from my iPhone using Audizine (http://r.tapatalk.com/byo?rid=87676)Thank you.

Just spent half an hour poking through that beast of a thread.

Not sure how I feel about the current solution in that thread. Just add a hose to the bleed tube, but then cap the end of the hose? Isn't that the same as capping the bleed tube?

How does the engine loop bleed work? It has a small tube plugged back into the reservoir.

- dubgli

[NohNoh]

Thank you.

Just spent half an hour poking through that beast of a thread.

Not sure how I feel about the current solution in that thread. Just add a hose to the bleed tube, but then cap the end of the hose? Isn't that the same as capping the bleed tube?

How does the engine loop bleed work? It has a small tube plugged back into the reservoir.

- dubgli

It would only work if you had a divorced coolant loop. If you see my setup in that thread I used a valve instead of capping it and I put a filter at the end.


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[dubgli]

It would only work if you had a divorced coolant loop. If you see my setup in that thread I used a valve instead of capping it and I put a filter at the end.


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I did see that. I didn't even realize that was you.

What does the filter do again?

So that is a one way valve that releases out? Sorry - could you explain please?

[MSq5]

It would only work if you had a divorced coolant loop. If you see my setup in that thread I used a valve instead of capping it and I put a filter at the end.


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May I ask, did the divorced system as you have it set up noticeably lower IATs? Maybe that info is in that thread. I’ll check it out now.

[Mike Literous]

Just in the process of replacing mine, the leak being evident with the coolant pooling in cylinder #3, and a small but persistent unexplained coolant loss. The first symptom was the occasional rough idle on cold startup which over time became more frequent. Car run perfectly otherwise. I removed the blower and pressure tested with 20psi of nitrogen, and bubble tested all the junction points, and yes the pressure went pretty well to zero in about 3-4 min. So only a small leak but a leak neatherless. Now the fun will begin sourcing a core in Australia for a reasonable cost. Do most of you chaps replace both or just the offending core.

[Allan691]

I have two spares sitting on a shelf in my garage.. I will probably replace both at the same time when the time comes..


Sent from Italy

2009 Eurospec B8 S4
APR Stage II