Turbo to Intercooler Pipe

[bazmac28]

Brought the new year in getting towed home by the AA . Just going up the slip road onto motorway and a loud bang , sort of popping noise . On this happening a loss off power and car sounding if exhaust is blowing badly . Phone AA out get towed off motorway so they can look at it . Turns out the pipe from the turbo to intercooler has blew off . It's down the front nearside . The AA guy can get it back on but he says it will blow off again as he could just pull it back off . The clip that holds it on sits in some lugs but something is amiss as this is not happening hence he can just pull it back off . First of all has anyone else had this problem . Secondly what would cause this and is it the signs of a more serious problem waiting in the wings ? Hopefully this is covered in the Seat approved used car warranty .

 

[CrispDust]

Will be covered under warranty. Its another crap design by VAG and is common to all TDI units - 1.9 and 2.0
The retaining lugs wear so the spring clip becomes next to useless. Hose that usually goes is one that goes into the bottom of the intercooler on the BKD engine, which suggests that there is a restriction in the intercoller causing additional pressure build up. Its even more of a problem on remapped engines.
The pipe can also come part off allowing an air leak, some loss of power and soot exhaust all the time.
Some including me have fixed it by careful use of self tappers.

 

[Deleted member 54479]

CrispDust, I've got a 1.9tdi Altea Stylance 2007 (standard 105bhp) I'd be interested how to identify this pipe. Any chance of a photo or a fuller description how to find it? Is there anything else worth doing?
Thanks bigsacs

 

[CrispDust]

sorry mate i'm not sure where this is on 1.9. The pipes maybe routed completely different to the 2.0 BKD. BKD has turbo at back of ngine whereas your turbo is at front!

 

[Deleted member 54479]

Thank anyway for replying. bigsacs

 

[bazmac28]

Thanks for the replies . The pipe that has come off on mine is located at the front nearside behind the bumper . I am only going off where the AA man was working and don't know if there is more than one pipe here . Could not even tell you what to look for as , as I saaid I am only going of where the AA man was working . It was from the underneath of the car . Hope this helps . Cheers Barry

 

[cherryone]

Had the same thing happen on my 2.0tdi this time last year - the lower intercooler pipe connections are a really poor design fortunately its not too an expensive job. It's only held on by half a thin circular metal clip that should secure against two lugs on the pipe. It transpired that the dealer broke one of them when they last replaced the seals.

 

[CrispDust]

driver's side? Sounds like intercooler pipe
cherry1 - yeah but when the lugs wear, which they do, its a whole new pipe at £80 or so. Stupid design but VAG won't change it.(cynics would not wonder why...)

 

[Wimbledonian]

Sorry to hear about your new year woes. I know the feeling.

I spent the previous new years eve in the company of the AA when my Zafira snapped its cambelt on the M4.

 

[milesyboy1]

Same thing happened to me on my last Altea. Scared the pants off me when it happened at 70mph! Like previously said it's a bad design and cost about £90 to put right, which isn't too bad considering I thought it was something much more serious.

 

[CrispDust]

But still £90 for something that shouldn't happen if they used proper design - ie trusted jubliee clips!

 

[bazmac28]

Wish it would have only been £90 to fix . Try just short of £500 the actual intercooler needed replaced and was not covered in the named components warranty . To say I am well pissed off is not even getting close . Cheers for the replies anyway guys . Baz

 

[pdh 14a]

Wish it would have only been £90 to fix . Try just short of £500 the actual intercooler needed replaced and was not covered in the named components warranty . To say I am well pissed off is not even getting close . Cheers for the replies anyway guys . Baz

Probably could have got a Forge aliminium one for less than that!

 

[CrispDust]

why did intercooler need replacement? I've not known one of these "go" before. The only thing that can go wrong is it gets a leak. Very difficult to imagine this can have happened unless damaged. Sorry to say this but sounds like you have been taken for a ride.

 

[bazmac28]

Apparrently the bit that the pipe goes onto with the lugs on it had part of it missing so the pipe would not go back on propery and the clip to hold the pipe on and stop it blowing off again . It's just the type of luck I have . It was a main Seat dealer I took it to and also where I bought the car . This dealer has a good reputation second to none . I did my homework on tham before I bought the car and was one of the main reasons I went to them . The dealer is Livingstons in Uddingston near Glasgow . I would love to hear if anyone has anything bad to say about them . It has ony good reports on here . Cheers Baz .

 

[CrispDust]

And did they sell you the warranty? It is an unusual case and since it is a known bad design I would be seeking some goodwill off of SEAT UK.
How long ago did you buy car?

 

[CrispDust]

ps they only reason I can think lug would break was if either:
1. Seat "technician" was previously hamfisted and damaged it.
2. It was a faulty/bad part in the first place.
From its position it would be extreemley difficult to get damaged in normal use and the surrounding engine cover and wheel arch would be damaged too.

 

[bazmac28]

Bought the car in June . I thought the same about it being really difficult to get damaged . I need to get the address or email for Seat UK so I can write them a letter , all I can do is see where I get with that . The car is an 05 plate with only 46000 on the clock and I think this is a premature failing and should last a lot longer than this . I think I am pissing in the wind to be honest but it's worth a go . Thanks for all your help and replies . Baz .

 

[CrispDust]

If you only bought it in June then dealer should repair. Ask them to explain why the lug is damaged.
Dealers are still subject to SoG act ie fit for purpose and not defective - clearly this was.

 

[Toxic]

My late died a death tonight on the way home. Loud bang, no power and black smoke. Was able to get a good look at the pipework it was dark, but I think mine has finally popped it's intercooler pipe. Won't know til tomorrow when I get a mate to have a look at the car.