Tdi intercooler removal

[barryg]

Hi
is it a big job to remove the I/C from the 150 fr? I have a nasty stain around the lower pipe connection (almost a drip actually) so things must be pretty mucky inside the i/c and im sure a dirty intercooler would restrict performance. had a look at it cant see much without taking off the underbody covers and i dont want to start into something i cant finish. If its just a few bolts and piping it would be ok. but i dont want to take out radiators bumper etc.. Anybody done it before???? Thanks in advance

 

[prc]

pretty big job there. The FMIC also has mounts for the radiator. make a CCV bypass and the IC will eventually clear out.

 

[magic77]

snap had a look at my crank case vent that goes into the air intake and the whole thing is leaking oil whats the simplest , cost effecting way to stop the waste oil being sucked back into the engine.

Also would the lack of oil effect the turbo in any way

 

[sssstew]

the lack of oil will not effect the turbo in anyway.

An old navy filter would be best but not sure you can get them over here, have a search on TDIclub.com for old navy for loads of info. and they look good!

 

[barryg]

pretty big job there. The FMIC also has mounts for the radiator. make a CCV bypass and the IC will eventually clear out.

Whats a ccv bypass? is it easily done? does it have any side effects?????

 

[sssstew]

CCV bypass means Crank Case Ventilation by pass, its the black puck on the top of the engine if you take the cover off, it vents the air off the top of the crank case back into the inlet, and hence the intercooler too.

Bypassing it means removing the link so it doesnt go back into the inlet. Theres loads and loads of info about it over on tdiclub.com, have a look over there too.

It is easily done if you can source the right parts. Side effects... no bad ones, just less oil back into the inlet which when combined with the EGR gas tends to soot up the intake.

 

[barryg]

souds good i will have a look for more info, thanks

 

[magic77]

has anyone on here done anything like this. Tons of good ideas on the tdiclub.com from using catch tanks and there are few on ebay to using tubing and fuel filters.

Just wondering if anyone has tried any of these in UK and how succesfull where they

 

[muddyboots]

My intercooler looked manky on the outside, but there wasn't a great deal of muck inside, just a teaspoon or so of oil collected at the bottom.
IIRC that was somewhere around 40-50k miles.

See here:

http://muddyboots.fotopic.net/p15502319.html
http://muddyboots.fotopic.net/p15502320.html

 

[muddyboots]

I think it's probably more effective to clean the dead insects and road gunk that starts restricting airflow through the fins.

 

[cheshire cat]

has anyone on here done anything like this. Tons of good ideas on the tdiclub.com from using catch tanks and there are few on ebay to using tubing and fuel filters.

Just wondering if anyone has tried any of these in UK and how succesfull where they

I have a seperator made in copper, which collects about 20ml/1000 miles, unfortunatly it only holds100ml and is a pain to empty, not got round to a Mk2 version yet

 

[magic77]

where abouts did you get yours from and how much was it

 

[muddyboots]

If it's the version I saw when I met Nic at Donington a year or two ago, the required parts are all available from the plumbing aisle at B&Q

 

[barryg]

if what i think is correct my intercooler (fr 150) is mounted across the front between the a/c rad and main radiator. so im guessing its a pig of a job to take out. but is it possible to even clean the outside easilly ???

 

[cheshire cat]

I have a seperator made in copper, which collects about 20ml/1000 miles, unfortunatly it only holds100ml and is a pain to empty, not got round to a Mk2 version yet

not quite B-Q but not difficult to make, cost approx£15 there was not a lot of interest at the time so if you want to have a go at one PM me