Ibiza Cupra TDI boost leak - intercooler pipework question

[MattSee]

Evening all,

2006 Ibiza Cupra TDi...

After noticing a smokey exhaust and a hissing sound (with the windows down) on acceleration, I think I've traced a potential boost leak to the pipework at the top of the intercooler. Just looking to see if others have seen similar, as most mentions on the forum are for the bottom pipework.

I've only removed part of the grille, after seeing tell-tale oil deposits, not the full bumper yet, so can't confirm 100% until I do this.

From what I can see, the charged airflow enters the intercooler at the bottom left (as viewed from the front) and exits at the top left, through a short length of jubilee-clipped rubber hose and then into a formed plastic pipe that has some form of pressure sensor. All nicely hidden behind the driver's side headlight and bumper...

Anyone else had similar ?
If so, did you replace or repair the pipe ?
What was the cost ?

Cheers !

 

[fuzzy232]

where are you seeing oil deposit ?

 

[MattSee]

Looking from the front, and pulling the bumper as far away as I dare, there is a film of oil all around the plastic pipe, so just to the left of the short rubber section. No pics, sorry.

It looks like the formed plastic pipe is injection-moulded or similar, and it has a seam, so it coud have splt on the seam?

I could just about touch it with a finger, given the difficult access, and it came away oily.

 

[mk4 cupra]

I'dike to know this becasue my Cupra tdi has a boost leak which I have found a very very slight leak from the intercooler but it still has another I know it does so am curious if this pipe cracks etc

 

[MattSee]

I'dike to know this becasue my Cupra tdi has a boost leak which I have found a very very slight leak from the intercooler but it still has another I know it does so am curious if this pipe cracks etc

Evening again, time for an update.

So...bumper off - well, removed, and rested on the ground (check separate threads, takes around 30 mins) and proceeded as follows, to remove plastic pipe completely:

1. Disconnect top jubilee clip on rubber hose by alternator, as access to lower clip was too hard
2. Remove driver's side headlight
3. Disconnect pressure sensor
4. Remove 2 x 10mm securing bolts
5. Disconnect 2nd jubilee clip on top of intercooler.
6. Wiggle it like f**k, plastic pipe will come out with rubber hose by alternator intact

Inspected pipe and no obvious splits, so blocked off one end with my hand, and put my mouth around the other and blew as hard as I could. Not very scientific, and nowhere near the 2-3 bar (?) that the Cupra can blow, but noticed a small hiss. Repeated test, after covering all of the moulded seams with a soapy solution. Bubbles appeared so looking more positive.

Refitted pipe (I guess there was no need to remove it after all!) and ran engine, with helper sat on driveway giving it the beans. Best test possble with no road load, by flooring it, up to around 4,000 rpm to create as much boost as possible, then foot off the pedal, and continually repeat.

Split then became very obvious after continually covering the seams in soapy solution. Bubbles, air leaking and hissing everywhere.

Pleased I found it. Not so pleased with the stealer price of £90 plus VAT, and there is no local or factory stock. Careful driving for the next few weeks, while I wait for a new one. SEAT part no is 6LL145935B. I may also try dark side developments, will post pics below

 

[cupra.al]

dont get the replacement seat part its well restrictive and by the sounds of it expensive.
i threw one away a couple of months ago it was left over from my 20vt but there the same part.
forge do a nice replacement that makes a nice difference to the pull well it did on the petrol anyway and they dyno proved it on a tdi and it made something like 7bhp which isnt much but you feel it.
think its about the same price as what you say the seat part is.