Crack in intercooler : Weld ?

[Snyere]

Hi,


P006A and "Onderhoud nu" (translated in "Service Now" ) diagnosis and limp mode . Caused by a small crack in the intercooler input along the welding edge.

Is welding (TIG) an option ? Any tips?

Lessons learned : though replacement of MAP and MAP sensor is adviced (what we did) , before doing that check for leaks and check intercooler (and yes, it requires removing the front bumper). We should have done an audible check at the front to convince us to remove the front.

Rgds

 

[TyphoonFiST]

Pics of intercooler ?

 

[Snyere]

Follow "pointer" : 4 cm crack.

 

[TyphoonFiST]

How did that happen? Yes it could be welded shut*

 

[Snyere]

"How did it happen?" : very good question. There was no external impact. Only overpressure possibly combined with weak welding ( intercooler is OEM) .
OEM recirculating valve was replaced with https://www.forgemotorsport.co.uk/R...or_Ford_Fiesta_ST_180_Mk7--product--1301.html , though without any ECU change. Why is it replaced ? Better quality than OEM . Could this valve have caused an overpressure at the intercooler ?

 

[Snyere]

Sorry for my ignorance , can you elaborate on "welded shut*" . donunderstand.

 

[TyphoonFiST]

Highly doubt it..... could be just a poor casted/welded end tank*

 

[TyphoonFiST]

Sorry for my ignorance , can you elaborate on "welded shut*" . donunderstand.

Its aluminium right? If so... you could MIG weld it.

 

[Snyere]

Intercooler is now in hands of someone who masters welding. Are awaiting for his opinion. New OEM intercooler is 246.64 euro ( excl TVA ) .

 

[Snyere]

Better picture.

 

[Snyere]

Welded (TIG) , painted ( pictures attached) , assembled : P006A and P2178 do not occur any more during a 15 minutes test drive . Question remains if this was indeed poor quality OEM .
FYI: One of the first steps in the proces was changing the sounder box as there was a teeny-weeny little crack in the flexible tube going to the sounder box .
Fear that remains : is there 'something' that causes such a abnormal high turbo pressure ruining the intercooler?
A pitty that it is quite a job to get access to the intercooler, we should have noticed it much sooner. A smoke test was not done as no equipment and would also have revealed the culprit.

 

[DangerMouse]

Welded (TIG) , painted ( pictures attached) , assembled : P006A and P2178 do not occur any more during a 15 minutes test drive . Question remains if this was indeed poor quality OEM .
FYI: One of the first steps in the proces was changing the sounder box as there was a teeny-weeny little crack in the flexible tube going to the sounder box .
Fear that remains : is there 'something' that causes such a abnormal high turbo pressure ruining the intercooler?
A pitty that it is quite a job to get access to the intercooler, we should have noticed it much sooner. A smoke test was not done as no equipment and would also have revealed the culprit.

That is not an OEM intercooler. OEM end tanks are plastic. Glad you got it fixed!

 

[M-Sport fan]

^^^EXACTLY! (Even in Europe/rest of world. )

 

[Snyere]

That is not an OEM intercooler. OEM end tanks are plastic. Glad you got it fixed!

Thank you for making the point. Now you say: no partnumer ( I asume C1BY-9L440-AD) was engraved which is unusual (even in Belgium). MEA CULPA Ford for daring questioning OEM quality.