Cracked intercooler on a 55' LT35

[cleanhands]

Have recently been having trouble with my LT35, seems everythings going wrong recently . This time ive got an oil leak which i first noticed dripping out of the front grill next to the TDI badge there was also a whistling noise similar to a split air pipe and it gets louder as you rev. After a quick look under the bonnet ive seen a 2inch crack to the right of the radiator where the oils come from. anyone any ideas why this has happened and what needs replacing and how much its going to cost? thanks, andy.

https://www.vwaudiforum.co.uk/forum/a...attach/jpg.gif

[ferretflasher]

Cannot tell from the poor picture but Im guessing that its the intercooler when you say theres a whistling noise that gets louder when you rev it up! Dont quite know where the oils come from either unless its some goop that gets in from the EGR input and mixes up with the general muck that is found inside inlet manifolds with EGR!!
Its the crimpped over ends that have let go by the looks on the header of the matix piece, its just making me think that somethings wrong with your blow-off valve and you have experienced a very high pressure inside the intercooler, its safe to assume that the crimped joint has just given up and blown its guts out!
Was the van pulling like a super super double turbo machine and were you experiencing a noticable increase in performance?? That wooshing whsitling noise is high pressure air escaping from the crimp joint. Take it off and a) carefully crimp it back with a vice and some soft jaws or b) buy a new or scrap unit and rifit. c) get the engine boost checked and see that the blow-off valve is working as it should to limit max boost!
HTH
FF

[cleanhands]

thanks for the reply, ive got it sorted now, what happened was a crack appeared in the wall of the intercooler allowing air out, the pressure of the air leak pulled the crimped edge around on its self opening it up more. had to get the unit replaced luckily its a company van so they foot the bill.