Intercooler Problem - please help!

Miniblob

Member
Hi there,

My car is a 2001 1.4 TDi 75bhp - remapped (to 100bhp ish, apparently!)
I've just had it confirmed in the workshop I use that my intercooler needs replacing!
I see there are some cheap options, (around the £63 mark) on ebay - are there any particular ones to avoid, or are they all similar?
I've not checked direct with Audi yet, but I'm assuming they'll be a bit pricier - and still, from what I've read, prone to the same failures.
I've seen there's an alloy intercooler that's had a few group buys on here, but can't justify that, even if there was one available!
Are there any other bits I should have replaced at the same time? Hoses, etc?
I saw someone here used silicon hoses - is a set available from somewhere?

Also, there are a few other bits I need to get - is there some kind of online parts catalogue for Audi?
I've always used realoem for BMW, which makes it really easy to look at a diagram and get the part numbers!
If not, I shall go to the Audi dealer and describe my way through some bits!!!

Cheers,
Rob.
 
I've seen there's an alloy intercooler that's had a few group buys on here, but can't justify that, even if there was one available!
I saw someone here used silicon hoses - is a set available from somewhere?
Hi Rob,

I am the supplier of both the ProAlloy intercooler and the silicone hoses. Both are currently available.

All the best,

Tom
 
Thanks guys...

I'm not a big fan of Euro/CP4L to be honest, but do use them for some bits from time to time. Most stuff I've had to actually order from them, they've ended up supplying incorrect parts! (For BMWs at least!)

Timmus, you have pm about the hoses!

Thanks Andy, I shall have a browse through there later!
 
Hi there,

I've only just managed to get this in the workshop to have the intercooler replaced, having had to crawl around and nurse it for the last 2k miles/3 weeks!!!
So the disaster is... the intercooler I have bought, does not have the correct size fitment for the pressure sensor!!!
The one on the car has an 18mm boost sensor and the new one appears to want a 12mm sensor!?!?

I've tried to search through here, but I can't work out if there's a definitive answer...
Should I be able to get an intercooler with the correct/18mm boost sensor fitment, or will I have to change the boost sensor for a smaller one???

I did check this was the correct part with the seller, offered up the vin number but they checked it from the reg.
Wasted a huge amount of the guys time (and my money) in the workshop now and had to bodge the old one back together!!!

Any help or links to the correct part(s) will be appreciated!!!
 
Any advice/ideas???

Can I get a new intercooler that accepts the 18mm boost sensor? (Is there a different part number or something?)
Or is it possible to swap the sensor for the 12mm one?
 

see part 2.
There are both 18 and 12mm alternative parts listed. If you go to the right hand column in the table, there is a button with two opposing arrows on it. Click this and it takes you to the aftermarket (and OEM) part numbers from various suppliers. The links from both of these sizes go to lists with different part numbers suggesting you should be able to obtain either 18mm or 12mm by looking for the appropriate part number.

Audi / VAG original parts usually recommended, however in interests of speed and sometimes cost, some of the aftermarket suppliers listed are also well worth using (I use Febi Bilstein and Bosch a lot), and it is quite possible you might be able to get one of them overnight on Amazon Prime or similar if you look hard enough.

Best of luck!
 
I am actually very disappointed that your garage did not know to order the correct smaller size MAP sensor. This alone gives me very little confidence in their ability to diagnose and work on the A2. I certainly would not be happy with them bodging the old intercooler back together rather than looking for a sensor for the new intercooler. This is not a new issue as only intercoolers that take the smaller sensor diameter have been made for many years now.

I fear the words "bodge" and this garage are well suited.
 
Robin - thanks.
So I assume there is no alternative intercooler and I just have to buy another sensor to fit it - and both the 18mm & 12mm are interchangeable without causing any issues or needing anything else?

Audifan - I can appreciate your opinion with the information given, but that's not the case at all. I know them well and they work on all of my cars. I usually provide all my own parts and they do whatever labour I request. The alternative sensor wasn't available to them that day and they had done no prior research/diagnosis, because I did it and arrived with parts and a list of jobs! When I researched the intercooler on here/online/with sellers, nowhere did I see any mention of needing to change the sensor, or that there were two sizes. The seller I bought the intercooler from checked my reg and told me that was the part I needed.
They had the car for a window of approx 6 hours before I needed it back and driving, so it was bodged back together at my request, (they did a smoke test and plastic weld on the intercooler, which has held for just over 200 miles so far!!!) as we couldn't get hold of an alternative intercooler or sensor. They also had an A4 list of other things on the car to get done for me, which they did.
They do not generally bodge, unless I force/ask them to and they certainly wouldn't/don't work like this with any other/normal customers - they don't normally let people supply their own parts, unless they know them and agree prior, because of obvious warranty/complaint possibilities.
I rely on my cars heavily and do huge mileage and will often drop the car in unannounced at 11am and need to drive away by 4.30pm, so they do what they can for me, at my request!
Thankfully they're also not going to charge me the full amount for the labour and will fit the car back in next week when I can get back there with the correct parts!
 
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