Member Since: 02 Nov 2016
Location: Surrey
Posts: 1026
InterCooler Testing
Hi All
I suspect I may have a leaky intercooler and would like to pressure test it without removing it from the car.
Question is are both the hoses that attach to the IC easily accessible without a major strip down?
If I can establish if I have a leak then I will devote a couple of days to a front end strip down.
I had all 3 hoses replaced this summer but I am still getting limp mode and a fault code;
P023D-21 (6Cool Manifold absolute pressure - turbocharger/supercharger
boost sensor A correlation - General signal failure - signal amplitude
Pete at BAS suspects a leaky intercooler.
Thanks
21st Sep 2017 7:11 pm
Oiley
Member Since: 17 Jan 2015
Location: Kent
Posts: 213
I had a blown intercooler just last weekend I got no fault code or display faults shown on mine, if you drive down the road and loads of black smoke out the back I would go for the replacing of the intercooler, got mine from island4x4 at a reasonable price, and 4 hrs to fit it.
recommend you get the tab and pins lock for it.
21st Sep 2017 7:43 pm
ClassikFan
Member Since: 02 Nov 2016
Location: Surrey
Posts: 1026
If I do have a leak I think it'll be a really small one. I only get a problem whilst towing.
21st Sep 2017 8:08 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13599
Re: InterCooler Testing
ClassikFan wrote:
Hi All
I suspect I may have a leaky intercooler and would like to pressure test it without removing it from the car.
Question is are both the hoses that attach to the IC easily accessible without a major strip down?
If I can establish if I have a leak then I will devote a couple of days to a front end strip down.
I had all 3 hoses replaced this summer but I am still getting limp mode and a fault code;
P023D-21 (6Cool Manifold absolute pressure - turbocharger/supercharger
boost sensor A correlation - General signal failure - signal amplitude
Pete at BAS suspects a leaky intercooler.
Thanks
hi mate
hope u don't mind me asking
have u cleaned ur map sensor
is ur turbo actuator arm is ok, can test by live data via the iid
Using a data logger function, monitor the turbocharger actuator position and command the actuator to 5% pulse width modulated (PWM), then 95% pulse width modulated (PWM) in 5% steps. Check the results. There should be a smooth curve between the minimum and maximum values.
21st Sep 2017 8:16 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13599
plus , often thought about someway of pressure testing ur intercooler / hoses , maybe building something cheap out of plumbing parts
Member Since: 02 Nov 2016
Location: Surrey
Posts: 1026
Map sensor is clean, actuator seemed free enough when I checked it in Jan. My car wiggles it on startup.
If I don't find a leak I will replace the MAP sensor before finally turning my attention to the turbo
I saw a simple way to test the intercooler using a cut up inner tube and the existing clips. Seal one end and fix the bit of innertube with the valve on the opposite end of the inter cooler and pump it up.
21st Sep 2017 9:29 pm
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20727
Member Since: 02 Nov 2016
Location: Surrey
Posts: 1026
When Geoff. did my gearbox flush he gave the D3 a few revs and there was a little bit of smoke.
21st Sep 2017 10:03 pm
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20727
Different kind of smoke test
Essentially, fills the inlet with a fine smoke, gently pressurises the whole intake system, and any leaks will be evident by the smoke leaking out My D3 Build Thread
Member Since: 02 Nov 2016
Location: Surrey
Posts: 1026
Re: InterCooler Testing
Using a data logger function, monitor the turbocharger actuator position and command the actuator to 5% pulse width modulated (PWM), then 95% pulse width modulated (PWM) in 5% steps. Check the results. There should be a smooth curve between the minimum and maximum values.[/quote]
How do I do this? I have GAP tool.
21st Sep 2017 10:05 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13599
hi mate
if u go into the live readings u can test each of the following
Boost Pressure Actuator
Boost air temperature
Manifold Air Pressure
Mass Air Flow Sensor A signal frequency
whilst driving, u press the red record button which will give u live data for up to 10 x mins
im under the impression the boost pressure actuator is the turbo actuator , hopefully someone more experienced will be able to say if that's correct or not
if ur using an ipad u can take a screen shot, email the results to urself or print them
hope that helps
22nd Sep 2017 2:23 am
SteveNorman
Member Since: 14 Oct 2005
Location: Somerset
Posts: 1144
I second what Mikey says. In A few seconds you can have the answer. A smoke machine will find a leak quickly.
Regards
Steve
22nd Sep 2017 5:50 am
ClassikFan
Member Since: 02 Nov 2016
Location: Surrey
Posts: 1026
Disco_Mikey wrote:
Different kind of smoke test
Essentially, fills the inlet with a fine smoke, gently pressurises the whole intake system, and any leaks will be evident by the smoke leaking out
I this something I can DIY or do I need to go to a garage?
22nd Sep 2017 10:12 am
adam
Member Since: 20 Sep 2005
Location: Home and Happy
Posts: 6917
Local indy bought one to test mine for leaks (which they found straight away) - don't think it was hugely expensive - believe they unclipped one of the large intake hoses and plugged it into that
22nd Sep 2017 10:34 am
SteveNorman
Member Since: 14 Oct 2005
Location: Somerset
Posts: 1144
You can do it yourself if you spend around £500 on a smoke tester
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