leaky stock intercoler or am i a crazy person??

Old Oct 9, 2010 | 05:44 PM
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leaky stock intercoler or am i a crazy person??

hey folks

sooooooo, i removed my STOCK STI InterCooler this afternoon and decided to clean it before i got to crazy with a series of projects i am starting. as i am washing the ic, i notice that when i have it tipped to one side, water is escaping from all over the place, along the seams of the pressed core.

i started to get curious, so i kinda filled the ic up so to speak to see if water was coming out anywhere other than the inlets/outlets. almost every corner seems to let water practically pour out. and it is def coming from between the seams.

am i crazy or aren't ic's suppose to be air tight? like have no pressure drop when pressurized to a certain point? like aren't they suppose to be SEALED???

any help or direction is appreciated. unless there is something i am missing, i might need a new ic....

keep in mind the car has 97k miles and it might be time to replace the old, heat cycled ic....

thanks!

josh

ps any place in the Bay that pressure tests?
Old Oct 9, 2010 | 05:53 PM
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It should definitely not be leaking from the seams! We can pressure test it for you... we do an overall system pressure test on most cars we work on.

Thanks
-- Ed
Old Oct 9, 2010 | 07:07 PM
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rock on ed

any recommendations on a replacement? short of another stocker?

and what about my heat cycled over 97k mi theory? any merit to this? and what i mean is the ic has heat cycled to the point where the seams are seperating(sp) slightly, or have worn unevenly over time. i am just guessing based on what i am looking at construction wise.

and i might take you up on the pressure test.....

josh
Old Oct 9, 2010 | 07:45 PM
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Whoa, that's weird man... I always thought they were supposed to be air tight as well, how else will it hold pressure? You dont have any problems while driving?
Old Oct 9, 2010 | 09:15 PM
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daniel

that is what i am trying to digest. i do have issues sometimes hitting boost up here, but that is to be expected. i am def going to have it pressure tested.

wtb. tmic for 2005 sti in the mean time...
Old Oct 10, 2010 | 09:15 AM
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Originally Posted by josh
rock on ed

any recommendations on a replacement? short of another stocker?

and what about my heat cycled over 97k mi theory? any merit to this? and what i mean is the ic has heat cycled to the point where the seams are seperating(sp) slightly, or have worn unevenly over time. i am just guessing based on what i am looking at construction wise.

and i might take you up on the pressure test.....

josh
While I haven't seen this before, it's certainly possible that the heat cycles overt the last ~100k miles have weakened the seams over time.

I'd replace with a stocker unless you're looking to upgrade the turbo later on. This is a very uncommon issues, so I wouldn't give up on the oem unit just yet.

Thanks
-- Ed
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