An intercooler suspected of failure will need to be pressure tested. Since pressure testing a force induction piping system while installed on the vehicle can result in oil being pushed into the charge pipes, the intercooler should be removed for testing. One end of the intercooler will be plugged, and the other end will receive a plug with a schrader valve. The valve, which is identical to the valve stem on a tire, will be filled with compressed air to the maximum pressure the turbocharger for that vehicle can produce. The caps sealing the ends will be checked for leaks, and the intercooler will be left to sit. If the intercooler loses pressure over time, it will be understood to have a leak, and detecting that leak will require spraying soap solution until bubbles are formed, or injecting smoke into the intercooler.
How are Intercoolers replaced?
Intercooler replacement, when replacing with a like unit, will require removal of mounting fasteners and disconnecting the intercooler piping from the ends of the intercooler. There should only be two total pipes of fairly large diameter. If the intercooler is locked in place by the front bumper, grill, or other components, those components or body panels will need to be removed prior to replacing the intercooler. Replacement of a bumper will be simplified by placing witness marks on the body panels with liquid chalk or bar soap.
RepairPal Recommendations for Intercooler issues
It is recommended to replace the seals for the intercooler piping any time the piping is removed. This is because an air leak in the intercooler piping can lead to under boost conditions which will have an adverse effect on engine performance.If replacing the intercooler for an aftermarket part, the size of the unit as well as the rate of airflow through the unit are necessary to consider. If the unit is too small in either way, the performance and efficiency are likely to be decreased.
What to look out for when dealing with Intercooler issues
Oil found in the intercooler is normal in small amounts, however, a large amount of oil found in the intercooler could indicate engine ventilation or turbocharger oil seal issues.
Can I replace the Intercooler myself?
Replacing the intercooler does not represent a challenge until body panels must be removed. Aligning the body panels may seem difficult or impossible when reinstallation occurs, but it can be done with some attention to detail and patience. If adding an intercooler to a vehicle that previously did not have one, this may be a job for a custom fabrication shop.
