Supercharger Intercoolers

[jfootlong24]

So just was curious to see if others have had any issues with their intercoolers because apparently mine are leaking again after just replacing them at 40k miles and at the time was only stage 2 for 5 k miles before the 1st set went on stock cooling.
So since then I have killer chiller and I'm at 47k miles and 7k miles later and I'm having the symptoms again misfire on start up and fluid loss in reservoir trying to see if I'm not the only one haven't read about to many issues with intercoolers on here


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[bhvrdr]

darn i'm holding my breath man. So to be clear your first set went after 5K on stage 2 with regular cooling and the second one lasted 7K miles on dual pulley? with killer chiller. What PR are you BTW? I'm at 3.17 and about 8k miles on stage 2 and up to 3.17pr now. I'm waiting for the inevitable.

Mike

[derek.kritz]

U have the aftermarket supercharge coolant pump too? Or the stock pump?


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[theweebabyseamus]

I'm starting to think that maybe the issue with the intercoolers is partly do to running an insufficient heat exchanger. If the heat exchanger isn't able to keep the s/c cooling temp low enough then it would make sense to have issues with leaks.

[jfootlong24]

darn i'm holding my breath man. So to be clear your first set went after 5K on stage 2 with regular cooling and the second one lasted 7K miles on dual pulley? with killer chiller. What PR are you BTW? I'm at 3.17 and about 8k miles on stage 2 and up to 3.17pr now. I'm waiting for the inevitable.

Mike

Yea went stage 2 at 35k had to replace them at 40k, went dual pulley afterwards with HX and reservoir, stock pump, PR was 3.11 and at 44k went with KC and AWE reservoir with upgraded AWE pump and upped the PR to 3.25 as well


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[jfootlong24]

U have the aftermarket supercharge coolant pump too? Or the stock pump?


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AWE pump


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[jfootlong24]

I'm starting to think that maybe the issue with the intercoolers is partly do to running an insufficient heat exchanger. If the heat exchanger isn't able to keep the s/c cooling temp low enough then it would make sense to have issues with leaks.

I think there getting to cold to fast is the issue, I have no HX so it goes straight into the blower


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[jfootlong24]

I've seen a post on here this week that was talking about more robust intercooler's but not sure how legit they are?


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[jfootlong24]

I kno me and loe can't be the only ones that have had this issue if so we have some bad luck then I guess, hoping to hear from some other members


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[derek.kritz]

I've seen 2 other cars at the shop I go to. Both people that had leaking intercoolers had the AWE pump. This is only 2 I know of. And not statistically valid I know. And may be a coincidence. Dunno. But the mechanic was thinking that the increased flow of the pump was putting too much pressure inside intercoolers. Pumping force goes up, so does velocity. Unfortunately, so does pressure.


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[abamfo]

I had it with bank 1, stock HE and pump... not sure this will make any difference but the intercoolers have been replaced with a new version from Eaton... it has a higher part number on ECS

[cjw]

Curious if the year of the car matters in these since it does seem like they revised these once.

[Loe]

My current ones are doing fine thus far, mine failed pre cooling and post. So for no issues with KC-only tho

[PinoyS4]

Mine failed at 8k miles

[skiptowncat]

101k miles and no issues yet.

[xpoweruk]

60k miles,no issues so far.

[B8Addict]

I hope this doesn't become a common failure. I don't believe there has been too many seen. Been stage 2 for 7k miles and have not had any issues(knock on wood).

[mgert31907]

What is the procedure to remedy this intercooler leak? Part replacement or refurbishment? What is the cost to DYI the fix. I am just starting on the S5 journey and am making a mental list of possible weak spots in the S5, and what to look out for. I am currently stage 2 APR single pulley. Has anyone had this issue with the APR heat exchanger? I was going with AMS or APR CPS system. Thanks.

[Loe]

I had it with bank 1, stock HE and pump... not sure this will make any difference but the intercoolers have been replaced with a new version from Eaton... it has a higher part number on ECS

I forget the revision #, but I believe mine was either suffix R or S. Previously I had D, then E, then F (yes I'm on my 4th set )

The worse part about this process is that it doesn't show up in leak-down or pressure tests, it reveals itself as a misfire (at idle, and then during high load situations) which fools you into thinking its the spark plug, coil pack, or fuel injector. The only true way to diagnose this is to pull it out to pressure test or closely monitor your coolant levels to see if they slowly go down. I actually have a feeling many are actually leaking, just leaking a very small amount to not make a significant impact to generate a full misfire code.

It's definitely good to have a spare pack if you are modded, particularly if you are pushing the larger amounts of air on a dual-pulley set-up. I would actually point fingers more towards air velocity over heat cycle, although I'm sure heat cycle does contribute to the matter, but this is just a guess.

[jfootlong24]

What is the procedure to remedy this intercooler leak? Part replacement or refurbishment? What is the cost to DYI the fix. I am just starting on the S5 journey and am making a mental list of possible weak spots in the S5, and what to look out for. I am currently stage 2 APR single pulley. Has anyone had this issue with the APR heat exchanger? I was going with AMS or APR CPS system. Thanks.

No fix for it, you can only replace them and there not cheap each intercooler is 250 and if u need new gaskets as well there almost the same price, so last time it cost me 1300$ and this time since I already have new gaskets it's probably going to b close to 1000$


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[jfootlong24]

I forget the revision #, but I believe mine was either suffix R or S. Previously I had D, then E, then F (yes I'm on my 4th set )

The worse part about this process is that it doesn't show up in leak-down or pressure tests, it reveals itself as a misfire (at idle, and then during high load situations) which fools you into thinking its the spark plug, coil pack, or fuel injector. The only true way to diagnose this is to pull it out to pressure test or closely monitor your coolant levels to see if they slowly go down. I actually have a feeling many are actually leaking, just leaking a very small amount to not make a significant impact to generate a full misfire code.

It's definitely good to have a spare pack if you are modded, particularly if you are pushing the larger amounts of air on a dual-pulley set-up. I would actually point fingers more towards air velocity over heat cycle, although I'm sure heat cycle does contribute to the matter, but this is just a guess.

Yea i do agree with that a lot may not even know about, I have yet to throw a full misfire code but everytime i start the car after being fully warm it misfires on start up but u actually have to log to catch it through vcds


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[ryanlada]

Tuned to stage 2 APR at 50k, still not leaking at 100k. Completely stock cooling system.

[B8Addict]

I forget the revision #, but I believe mine was either suffix R or S. Previously I had D, then E, then F (yes I'm on my 4th set )

The worse part about this process is that it doesn't show up in leak-down or pressure tests, it reveals itself as a misfire (at idle, and then during high load situations) which fools you into thinking its the spark plug, coil pack, or fuel injector. The only true way to diagnose this is to pull it out to pressure test or closely monitor your coolant levels to see if they slowly go down. I actually have a feeling many are actually leaking, just leaking a very small amount to not make a significant impact to generate a full misfire code.

It's definitely good to have a spare pack if you are modded, particularly if you are pushing the larger amounts of air on a dual-pulley set-up. I would actually point fingers more towards air velocity over heat cycle, although I'm sure heat cycle does contribute to the matter, but this is just a guess.

Loe what are the chances do you think of it occurring on a conservative stage 2 setup? Unitronic for example. You stated that its likely more air velocity that is causing this failure but I do wonder how much of a role heat has in accelerating this. I am concerned if I need to upgrade cooling ASAP to protect against this. Im currently at 68k.

[jfootlong24]

Loe what are the chances do you think of it occurring on a conservative stage 2 setup? Unitronic for example. You stated that its likely more air velocity that is causing this failure but I do wonder how much of a role heat has in accelerating this. I am concerned if I need to upgrade cooling ASAP to protect against this. Im currently at 68k.

It's hard to really say what the true cause is but fwiw after 5k miles of stage 2 and on stock cooling they started leaking for me idk if living in hot Florida might have a role to play into that


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[B8Addict]

It's hard to really say what the true cause is but fwiw after 5k miles of stage 2 and on stock cooling they started leaking for me idk if living in hot Florida might have a role to play into that


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Strange. People have been stage 2 for many many years and people are just mentioning failing intercooler cores now. Hopefully we can find out what causes the failure.

[EIAlfonso]

I was at 25K mile or so when I went Stage 2

I went Stage Dual 2 Pulley at about 45K (3.18 ratio), added additional HE, at 48K Miles started having issues at start up and had both ICs replace
I believe they were leaking before DP, DP may have put it over the top

I logged some runs a few weeks ago when it was mid 90's out and my IAT's reached 90C (60C starting point) on 0-120mph taking it a little easier in the summer months now knowing what I know

Trying to shift before 7K when its over 90 degrees outside

[TexasDfwS4]

I think all the bolts Audi uses are stretch and once you open Pandora's box then the problems start. But pay to play...

[jfootlong24]

I was at 25K mile or so when I went Stage 2

I went Stage Dual 2 Pulley at about 45K (3.18 ratio), added additional HE, at 48K Miles started having issues at start up and had both ICs replace
I believe they were leaking before DP, DP may have put it over the top

I logged some runs a few weeks ago when it was mid 90's out and my IAT's reached 90C (60C starting point) on 0-120mph taking it a little easier in the summer months now knowing what I know

Trying to shift before 7K when its over 90 degrees outside

Yea with the killer chiller my iats are pretty stellar with a 3.25 ratio, 0-120 for me starting point 36*C and finish at 60*C in 90F heat ,so I don't think there leaking because of heat


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[jfootlong24]

Strange. People have been stage 2 for many many years and people are just mentioning failing intercooler cores now. Hopefully we can find out what causes the failure.

Yea it doesn't make any sense to me, I wish there was another option for intercooler cores, just doesn't make sense to be spending a 1000$ every 10k miles for intercoolers, mine as well buy a used blower for 6 to 800 $


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[jfootlong24]

So sometime this week or the next I'm going to talk to two shops in my area that supposedly can make stronger cores, another member on here told me about them so I'll report back with hopefully a solution finger crossed!!


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[B8Addict]

So sometime this week or the next I'm going to talk to two shops in my area that supposedly can make stronger cores, another member on here told me about them so I'll report back with hopefully a solution finger crossed!!


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This is awesome news! Hopefully they can figure out what causes them to fail, too.

[jfootlong24]

This is awesome news! Hopefully they can figure out what causes them to fail, too.

Yea I hope so as well, if not then I'm almost forced to not have fun with the car because it will b an ongoing thing for me it seems, so time will tell.



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[DBFL]

So sometime this week or the next I'm going to talk to two shops in my area that supposedly can make stronger cores, another member on here told me about them so I'll report back with hopefully a solution finger crossed!!


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I found the information for the second shop. They are in the Orlando area, so LHT would definitely be more convenient. I'll give them a call tomorrow. I'll text you after I speak to them and let you know what they say. Maybe we should get a list of people that are interested. I'm sure the more we buy, the lower the cost.

[mgert31907]

We should get a group buy going for everyone that is interested in making more power as this seems to be a weak point in the system. I am definitely interested.

[DBFL]

We should get a group buy going for everyone that is interested in making more power as this seems to be a weak point in the system. I am definitely interested.

I can work on that. I'll call the two shops tomorrow to see what our options are and how long it'll take to manufacture them.
Anyone that is interested should comment in this thread so I can let them know how many sets we'll need.

[B8Addict]

If anything, we should also poll and see what tune's people are running that have had their intercooler cores fail.

[mgert31907]

Thank for getting that info DBFL. That is a great idea on the poll also.

[bhvrdr]

Have you all been following this thread too. Bell has something for us

http://www.audizine.com/forum/showth...IC-Core-Option

[jfootlong24]

Have you all been following this thread too. Bell has something for us

http://www.audizine.com/forum/showth...IC-Core-Option

I did see that, I'm assuming these have been test fitted and flow tested?


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[crumbta]

Have you all been following this thread too. Bell has something for us

http://www.audizine.com/forum/showth...IC-Core-Option

So sometime this week or the next I'm going to talk to two shops in my area that supposedly can make stronger cores, another member on here told me about them so I'll report back with hopefully a solution finger crossed!!

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I found the information for the second shop. They are in the Orlando area, so LHT would definitely be more convenient. I'll give them a call tomorrow. I'll text you after I speak to them and let you know what they say. Maybe we should get a list of people that are interested. I'm sure the more we buy, the lower the cost.

I think it would be somewhat safe to say, anyone participating in the current buys for the Mertop Headers and Merc Racing (threads) would be interested. Given that it now seems we have contact with Bell and looking like 2 other manufacturers / suppliers, this could bode well for our platform. I'd be interested in upgrading my cores after seeing a bit of data. I'm still amassing the parts I need to do things with only pulling the engine once.