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.

 

[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