Intercooler Cracked...TWICE!

[SeetLeeOn]

Hi

I own a 2006 2.0 TDi 140bhp Seat Leon. Last week i noticed a whooshing sound under acceleration, sounded like air escaping from somewhere. After taking it to a mechanic, i was told the intercooler housing, where the boost pipe goes into, is cracked and i would need a new intercooler. As it was bank holiday weekend, i persuaded the mechanic to do a temp fix shown below:

(i am unable to post URL to other sites)

Ive since replaced the intercooler for a brand new OEM, but after an hour of use, the same problem occurred. When i was driving, in second, i put my foot down and heard an almighty BANG, lots of smoke, and the car just kept jerking back and fourth under acceleration. The brand NEW intercooler i had just replaced cracked the same way as the old one:

(i am unable to post URL to other sites)

Ive had past "over boost" issues, which ive solved by switching the engine off/on.

Has anyone else had similar issues?
Could it be the turbo over boosting and not causing the car to "limp mode", but instead, the added boost is sent into the cooling system, increasing pressure, causing the weakest point to fail?

Any light shed on this matter would be greatly appreciated.

Thanks.

 

[Marshall]

Have you actually seen the split intercooler?
This sounds more like a pipe has burst or popped off.

 

[SeetLeeOn]

Yes, i have pictures of both. The intercooler is clearly cracked which causes the pipe to come out and/or boost pressure loss. Its happened to both intercoolers, the original and the replacement.

 

[Marshall]

Could there be a problem with your engine or gearbox mountings causing the engine to rock and pulling on the hose causing it to crack?
I can't see how your turbo would create enough boost to split intercoolers as it would go in to limp home first and or split a pipe.
Strange but requires more investigation I think.

 

[SeetLeeOn]

This is exactly what i stated to the mechanic, i would thought the limp home would kick in if it detects an issue. I asked the mechanic to check engine and gear box mounts and he replied, with a condescending tone, addiment its the turbo causing this and to feel free to take it to another garage (not many people like to be second guessed?)
I was hoping the mechanic could "blag" me a replacement intercooler, giving the split one back, so i was relunctant to go elsewhere.
i'm hoping he is correct, and not just pointing fingers at possible causes and replacing them for fun.

 

[Marshall]

You need somebody with vcds to plug in and check for any codes and check what boost is being created.
I'd be 99.9% sure the car would to allow the turbo to boost this high also pretty sure the intercooler pipes pop off if too much boost is present.

 

[lc_allan]

How much was a brand new intercooler?

 

[silver surfer]

did you replace to pipe as well as its normally ware on the pipe which causes it to pop out and can brake the intercooler

 

[LilyVictoria]

did you replace to pipe as well as its normally ware on the pipe which causes it to pop out and can brake the intercooler.

I also had a similar case before. And I changed the whole pipe and its ware as well.

 

[meeka]

Hi

I own a 2006 2.0 TDi 140bhp Seat Leon. Last week i noticed a whooshing sound under acceleration, sounded like air escaping from somewhere. After taking it to a mechanic, i was told the intercooler housing, where the boost pipe goes into, is cracked and i would need a new intercooler. As it was bank holiday weekend, i persuaded the mechanic to do a temp fix shown below:

(i am unable to post URL to other sites)

Ive since replaced the intercooler for a brand new OEM, but after an hour of use, the same problem occurred. When i was driving, in second, i put my foot down and heard an almighty BANG, lots of smoke, and the car just kept jerking back and fourth under acceleration. The brand NEW intercooler i had just replaced cracked the same way as the old one:

(i am unable to post URL to other sites but visit https://fmwhat.download/)

Ive had past "over boost" issues, which ive solved by switching the engine off/on.

Has anyone else had similar issues?
Could it be the turbo over boosting and not causing the car to "limp mode", but instead, the added boost is sent into the cooling system, increasing pressure, causing the weakest point to fail?

Any light shed on this matter would be greatly appreciated.

Thanks.

If your turbocharger is producing excessive boost pressure, it could potentially cause increased pressure in the intercooler and lead to failures, such as cracking. This could be due to a malfunctioning wastegate, a boost control issue, or other factors. It might be worth having the turbocharger and its associated components inspected to ensure they are functioning correctly.
If the intercooler is not installed correctly or if there are fitting issues with the pipes and connections, it could create stress points and lead to cracks. It's important to ensure proper alignment and secure connections during installation.

 

[jannyjazz]

Hey there! That sounds like quite the automotive mystery. While I'm not a car expert, a sudden "BANG" and smoke could indicate a significant pressure issue. Overboosting could indeed be a culprit, possibly causing stress on the intercooler.

Considering your past "overboost" issues, it might be worth checking the turbocharger and the associated components. A malfunctioning wastegate or a faulty boost pressure sensor could contribute to overboost situations.

Additionally, inspecting the engine management system for any latest version error codes or abnormalities might provide valuable insights into the root cause.

It could be beneficial to consult with a specialized mechanic or a Seat Leon enthusiast forum where others might have faced similar issues. They could provide more targeted advice based on their experiences with similar models.

Stay safe on the road, and I hope you get this issue sorted out soon!

 

[JavierEscuella92]

Hi

I own a 2006 2.0 TDi 140bhp Seat Leon. Last week i noticed a whooshing sound under acceleration, sounded like air escaping from somewhere. After taking it to a mechanic, i was told the intercooler housing, where the boost pipe goes into, is cracked and i would need a new intercooler. As it was bank holiday weekend, i persuaded the mechanic to do a temp fix shown below:

(i am unable to post URL to other sites)

Ive since replaced the intercooler for a brand new OEM, but after an hour of use, the same problem occurred. When i was driving, in second, i put my foot down and heard an almighty BANG, lots of smoke, and the car just kept jerking back and fourth under acceleration. The brand NEW intercooler i had just replaced cracked the same way as the old one:

(i am unable to post URL to other sites)

Ive had past "over boost" issues, which ive solved by switching the engine off/on.

Has anyone else had similar issues?
Could it be the turbo over boosting and not causing the car to "limp mode", but instead, the added boost is sent into the cooling system, increasing pressure, causing the weakest point to fail?

Any light shed on this matter would be greatly appreciated.

Thanks.

Hey there,

Sorry to hear about the trouble you're having with your Seat Leon. That whooshing sound under acceleration definitely sounds concerning. It's strange that even after replacing the intercooler with a new one, you're still experiencing the same issue.

The bang and smoke you described after accelerating sound pretty serious. It's possible that there could be an issue with overboost causing excess pressure in the cooling system, leading to the intercooler cracking. Overboost issues can sometimes cause jerking and erratic behavior in acceleration, so that could be a possibilityYoWhatsApp.

I'd recommend getting your car checked out by a mechanic who specializes in turbocharged engines. They might be able to diagnose the root cause of the problem and provide a solution. Hopefully, it's something that can be fixed without too much trouble.

Best of luck, and I hope you get your Seat Leon back up and running smoothly soon!

 

[goranjean]

Hi

I own a 2006 2.0 TDi 140bhp Seat Leon. Last week i noticed a whooshing sound under acceleration, sounded like air escaping from somewhere. After taking it to a mechanic, i was told the intercooler housing, where the boost pipe goes into, is cracked and i would need a new intercooler. As it was bank holiday weekend, i persuaded the mechanic to do a temp fix shown below:

(i am unable to post URL to other sites)

Ive since replaced the intercooler for a brand new OEM, but after an hour of use, the same problem occurred. When i was driving, in second, i put my foot down and heard an almighty BANG, lots of smoke, and the car just kept jerking back and fourth under acceleration. The brand NEW intercooler i had just replaced cracked the same way as the old one:

(i am unable to post URL to other sites)fmwhatsApp

Ive had past "over boost" issues, which ive solved by switching the engine off/on.

Has anyone else had similar issues?
Could it be the turbo over boosting and not causing the car to "limp mode", but instead, the added boost is sent into the cooling system, increasing pressure, causing the weakest point to fail?

Any light shed on this matter would be greatly appreciated.

Thanks.

Hello,
I'm sorry to learn about the difficulties you're facing with your Seat Leon. The whooshing sound during acceleration is indeed worrisome. It's puzzling that even after installing a new intercooler, the problem persists.
The described bang and smoke following acceleration sound quite severe. There could be a potential issue with overboost, leading to excess pressure in the cooling system and causing intercooler damage. Overboost problems may also result in jerky and unpredictable acceleration.
I recommend consulting a mechanic with expertise in turbocharged engines to inspect your car thoroughly. They can identify the underlying issue and propose a solution. Hopefully, it's a fixable issue without significant complications.
Best of luck, and I hope your Seat Leon gets back to smooth operation soon!

 

[Manic172]

I think it might have been fixed by now... only guessing tho... the original post was from over 10 years ago.... or its now a garden ornament

 

[johndolan]

It sounds like you're dealing with a frustrating and potentially dangerous issue with your Seat Leon. From your description, it seems like the problem might be related to overboost causing excessive pressure in the intercooler system, leading to cracks and ultimately failure.

One possibility is that your turbocharger is producing too much boost pressure, which could overwhelm the intercooler and other components of the intake system. This could explain why both the old and new intercoolers cracked in the same way.

The fact that you've experienced "overboost" issues in the past adds weight to this theory. It's possible that your turbocharger is operating outside of its normal parameters, causing intermittent spikes in boost pressure that the system isn't designed to handle.

If this is the case, it's crucial to address the root cause of the overboost problem rather than just replacing the intercooler repeatedly. A thorough inspection of the turbocharger, wastegate, boost control system, and related components is warranted to identify any underlying issues.

for more info you can check https://fmwhatsdownload.com

Additionally, it might be beneficial to consult with a specialist or experienced mechanic who has dealt with similar issues in Seat Leon models. They may have specific insights or recommendations based on their expertise.

Overall, addressing the overboost issue should help prevent further damage to your intercooler and ensure the long-term reliability and performance of your vehicle.