1.9 TDI 100BHP Intercooler Pipes

**mcgowan.b** · 05-04-2011,06:29 PM

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** · 05-04-2011,08:17 PM

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

**mcgowan.b** · 05-04-2011,08:28 PM

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

**mcgowan.b** · 06-04-2011,10:08 AM

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?