Leaking intercoolers.... Options?

[skyegtb]

So, changed my oil yesterday and found that both my intercoolers have oil residue and staining at the bottom - brilliant :cry: Seems like another item to add to the list of substandard parts fitted to our RS6's.
I am now unsure what best to do. I imagine these intercoolers are repairable, probably the best way by sending them to a radiator specialist for re-welding, but as my car runs considerably higher than standard boost due to the MTM568 conversion I wonder if they would even hold up then. The leak is visible at the bottom seams due to the oil stains but I can see no reason why the top of the intercooler would not be leaking as well.
Obviously fitting new OEM intercoolers is a (cheaper) option but to be honest I am not a great fan of fitting new parts without looking at the available upgraded options. Also, I am not keen on fitting parts that will likely fail again...
I know there are 2 other alternatives available - Wagner and Sportec, but sadly my budget cannnot justify these at the moment.
I have also seen a few RS6's on the internet with proper front mount intercoolers and there is a kit available for the 2.7TT Audis, but I doubt this would fit the RS6. I would quite like to go down the full FMIC route as I have done 2 custom installatons in the past with excellent results on my Legacy TT and my Saab convertible. Does anyone have experience of FMIC on RS6? Can anyone offer advice? Is there any other options I should also consider here?

[snoopra]

Sportec is pricey, not sure about the cost for Wagner. FMIC requires lots of MODs. Purchasing the OEM's and having a shop reenforce them may be another option.

[Bigglezworth]

http://www.rs6.com/forum/showthread.php?t=18725

[DHall1]

The time and trouble to try and JBWeld a failure joint is not worth my time. I dont wish to do this 3 times just to have it last 3 months.

Whatever you think of the stock parts they perform and have lasted 6 years.

If cost is an issue and the Wagners are too much. (Have you checked with Grizz?). Then I would find a discount Audi retailer and buy the stock intercoolers.




So, changed my oil yesterday and found that both my intercoolers have oil residue and staining at the bottom - brilliant :cry: Seems like another item to add to the list of substandard parts fitted to our RS6's.
I am now unsure what best to do. I imagine these intercoolers are repairable, probably the best way by sending them to a radiator specialist for re-welding, but as my car runs considerably higher than standard boost due to the MTM568 conversion I wonder if they would even hold up then. The leak is visible at the bottom seams due to the oil stains but I can see no reason why the top of the intercooler would not be leaking as well.
Obviously fitting new OEM intercoolers is a (cheaper) option but to be honest I am not a great fan of fitting new parts without looking at the available upgraded options. Also, I am not keen on fitting parts that will likely fail again...
I know there are 2 other alternatives available - Wagner and Sportec, but sadly my budget cannnot justify these at the moment.
I have also seen a few RS6's on the internet with proper front mount intercoolers and there is a kit available for the 2.7TT Audis, but I doubt this would fit the RS6. I would quite like to go down the full FMIC route as I have done 2 custom installatons in the past with excellent results on my Legacy TT and my Saab convertible. Does anyone have experience of FMIC on RS6? Can anyone offer advice? Is there any other options I should also consider here?

[hahnmgh63]

They may be 6 years old but they are aluminum intercoolers with little use on most RS6's. My Porsche's (x2 cars) are '86 & '87 respectively and both with more miles and both using more boost and neither of those have failed. They are substandard quality, they do not have caustic fluid like antifreeze to deal with like a radiator that lasts 100k + and deals with high temps and equal pressure. My old Audi S6 was at 150K and 10 years old when it was wrecked with a good intercooler.

[mcmuli]

i have a set of intercoolers here with only 7380 KM for togethter 600 Euro. They look almost new. i can ship to the US.

[mcmuli]

if you want the 2 extra watercoolers too, the price is plus 150 Euro so alltogether 750 Euro
Newprice for these 4 coolers is about 1300 Euro

[snoopra]

Does anyone have installation pics for the Sportec IC and oil cooler kit?

[DHall1]

Not really a discussion on is 6 years reasonable for the lifespan of RS6 intercoolers.

The question from the poster was. What do I do now with leaking intercoolers?

Stock new
Repair old
Sportec
Wagner

If Sportec and Wagner are too much money then it leaves stock or repair stock.

I say buy new stockers.

[p3u]

Question, why do leaking intercoolers have oil in the bottom?

[V8weight]

It's just a byproduct of the PCV system circulating through the intake. Positive crankcase pressure creates "blow by", which is oil forced past the rings, which is then vented back into the intake. I would assume that if you were to run a catch can in lieu of the the factory pcv system that you would no longer have oil circulating throughout the intake track.

[Brav]

I am currently investigating another aftermarket solution that should cost significantly less than current options. If I can get 5 people or so together should be able to get the price down further. They did a custoknm unit mor my noble M12 which was way more efficient and higher capacity with beautiful welds. Ill try to post more info soon.

[hahnmgh63]

Let us know Brav, I may be in the market in the next 6 months or less. I have a spare for the left side but my right side is leaking. Oh well.

[RS6-4dr911]

on your aftermarket solution Brav? Several had made comments about creating their own design, so far nothing. I'd be willing to bet Wagner's a cheap solution compared to making something from scratch.

[Brav]

Sorry I get sidetracked.. Ill hopefully have more info in the next few weeks, been busy around holidays, etc.
<input id="gwProxy" type="hidden"><!--Session data--><input onclick="jsCall();" id="jsProxy" type="hidden">

[DuckWingDuck]

chris, what's new man, how are things? we should try to get together soon

[hahnmgh63]

I'm in the middle of my Wagner install. Venair screwed up the shipping of my Intercooler hoses so I'm waiting on them right now. The Wagner's look good. Look to be of the same design as stock only thicker and of better quality. The welds look better, the finish looks better, the intake and exhaust pipes are polished very smooth. Just better quality and bigger. I still haven't gotten around to pressure testing my old ones yet (I'll get to it this week) but I'm sure my right side was leaking and not sure about the left. I purchased these through the 034 Motorsports group buy for $1750 and they may still be available at this price, check with 034.

[Lupo911]

to, bad, i could have shipped ours with your coolers...
our lower hose is longer then the OEM one

http://www.wagner-tuning.de/produkte/1247.php
http://www.wagner-tuning.de/images/produkte/RS64BIntercooler/RS6Schlauch1.JPG

[hahnmgh63]

I wish I had known that you had a set Lupo. Although, the Venair set is a 6 piece and I would like to replace all of them. There are 2 hoses on each side at the bottom and 1 on each side at the top. I would hate to leave one stock rubber hose down there for a weak link.

[Brav]

Anyone have a stock cooler laying around I could borrow/buy/rent for testing? I only have one useable car at the moment and thats my RS :)

Want to measure thermal efficiency, pressure drop, etc etc.
<input id="gwProxy" type="hidden"><!--Session data--><input onclick="jsCall();" id="jsProxy" type="hidden"><input id="gwProxy" type="hidden"><!--Session data--><input onclick="jsCall();" id="jsProxy" type="hidden">

[hahnmgh63]

I've got two drivers and one passenger side. I'm almost positive the passenger side is leaking and of course the spare I have is the drivers side.

[Brav]

I've got two drivers and one passenger side. I'm almost positive the passenger side is leaking and of course the spare I have is the drivers side.

Well both would be ideal for measurements, etc. Just need 1 functioning unit to do testing on.
<input id="gwProxy" type="hidden"><!--Session data--><input onclick="jsCall();" id="jsProxy" type="hidden">

[Brav]

chris, what's new man, how are things? we should try to get together soon

Sorry just saw your post.. just floating cars to Italy, biz as usual :)
<input id="gwProxy" type="hidden"><!--Session data--><input onclick="jsCall();" id="jsProxy" type="hidden">