1.9 TDI 100BHP Intercooler Pipes

[mcgowan.b]

Hi

On the above car, looks like the back spud to lock the intercooler into the car (see diagram below) broke off and there was a bodge fix to patch the hole. I've looked into it, and it all seems ok
I put it back on and locked the pipes into their sockets but once the turbo kicked in at 3k revs, it blew the lower feed pipe off again.

So the pipe feeding the air to the intercooler keeps blowing off, which would lead me to believe that the intercooler would be blocked somehow but I can't see anything in it causing a problem.

Is there likely to be a blockage further up the line, or what would be causing the pipe to blow off? The pipes look to be locked in securely. It blows off every time the turbo kicks in at 3K revs

[martin1810]

This is quite common when the pipe connecting ends are worn. You may have to replace the pipe.

[mcgowan.b]

Would it be as simple as that? They were bodged on with cable ties. would this work as a solution?

[mcgowan.b]

I had another look around under the bonnet yesterday evening and I managed to get the intercooler pipes held on with some jubilee clips. The heater plug light starts flashing on the dash when the revs go up.

The intercooler pipes are staying on, but at about 3.5k revs she will splutter a bit and lose power. I'm thinking that the patch on the intercooler isn't working right and the power loss is due to a leak.

Any Suggestions?

[martin1810]

Buy a cheap vag-com cable and cd from ebay and scan the car for faults. You need a laptop.

[mcgowan.b]

Will Autoboss V30 do it? I know I can get my hands on that one.

[martin1810]

Yes that should be ok for a fault code read.

[mcgowan.b]

Ok, I replaced the intercooler and its all fine, and have had the codes read.

She is now, however taking herself into limp mode occasionally when you are driving, and its not necessarily when the revs are that high.

For example, if you thrash it out in second and third its not a problem. If you're tipping away in fourth and starting to move on, it may hop into limp mode. A quick on / off of the key resets it. You could be at about 2.5k revs, and it wouldn't happen at 3.5k revs.

According to Autoboss, the code I'm getting is P1557: Turbocharger overboost control limit exceeded, or Charge pressure control: Positive deviation. As the off on with the key resets limp, I don't think its the MAP. I think the vanes in the turbo are sticking causing the problem.

Without having to go through the trouble of removing the turbo from the car, is there a cleaner that can be used to shift the carbon deposits?

Halfords have this stuff, but is it worth it?

Any advice / suggestions as always appreciated.

[martin1810]

I doubt that product will do any good. You could try inotec turbo cleaner, but that rarely works long term. Taking it off and cleaning the turbo vanes is the only real solution. This is a common problem. Just do a search on turbo overboost.