Help requested please.

serviced car today and noticed that the intercooler I fitted 18 months ago is blowing up on a couple of the rails like someone has connected a high pressure line to it. Anyone else had similar problem with aftermarket product?

Not got any error codes for it and car runs ok.

It did sound a bit more throaty when fitted, but has run ok since.

Got a Bluefin remap so could that be putting the turbo into overboost?

Is it just an inferior part? if so, where best to get another one? Big price differences from £90 ish to £250 for genuine.

TIA Andy
Freelander2 HSE (59 Plate, MY10 spec)

Finally got round to changing intercooler.

Don't think it's meant to be like this:h







Comparison


New one fitted

 Andy
Freelander2 HSE (59 Plate, MY10 spec)

crikey - from where did you get the blown up intercooler ? Jules

The new one looks a bit longer, or is it an optical illusion? Procrastination, mankind's greatest labour saving device!

Acoustic insulation ARB TPMS 3xARB air compressors After cooler Air tank On-board OCD pressure air/water cleaning Additional 50L fuel Carpet in doors ABE 2x1kg Waeco 28L modified fridge Battery 4x26ah Solar 120w Victron MPPT 100/20 DC-DC 18amps 175amp jumper plug Awning 6x255/60R18

Had one of them too. Was a cheapo unbranded thing from Ebay...

jules wrote:

crikey - from where did you get the blown up intercooler ?

Lightwater wrote:

The new one looks a bit longer, or is it an optical illusion?

Wowser, most likely inferior part, as you say buy cheap buy twice.
Saw that not so long ago on a Renault and that too was an eBay part.
Fingers crossed now this one holds together. Jaguar x-type sport gone
Jaguar x-type 2.2d sport one of my best cars ever sadly gone
Freelander 2 GS auto 2008 most unreliable ever ! gladly gone
Freelander 2 GS manual 2013 only time will tell !

The fins between the tubes not only provide the surface are for the heat exchange they also provide structural integrity . They are vacuum brazed onto the tubes which will be lucky to have a wall thickness of 10 or 12 thou . It looks like the fins on the unit in the photos have not been correctly brazed . I worked for IMI when they were first introducing Aluminium cored , plastic header , heat exchangers , way back in the late 1970’s . 2009 GS Auto Zermatt Silver - Sold June 21 after 10 years of ownership

2016 Subaru Outback SE 2.0 diesel SE Premium Lineartronic Sold 2024 after 8 years and 80k miles . Best Car I ever owned !

2023 Toyota Hilux invincible X 2.8 Auto .

Same issue here. A Britpart intercooler was fitted some years ago. I have had turbo issues, so I put my bet on that the balloning was caused by turbo overboost, but may not?? Turbo recently replaced, so that one seems to work at least..

Anyone know what the max turbo boost pressure should be?

Seen about 22psi on full load using Bluetooth odb adaptor and torque app, which is not giving any over boost error codes, so I assume this is ok.

Just wondered if this had impact on intercooler failure. Andy
Freelander2 HSE (59 Plate, MY10 spec)

The book says (pre 2011 TD)

During turbocharger operation, the turbine and compressor shaft may reach speeds in excess of 200,000 rpm, and produce
a charge air (boost) pressure of up to 1.7 bar (25 psi). A pre-turbine pressure of 3 bar (44 psi) and a temperature of 800°C
(1472°F) may be generated inside the turbine chamber. FL2 XS SD4 Auto 2010 2012-2017 (21k - 91k miles) (MY2011)
FL2 Metropolis SD4 Auto 2014 2017- (16k - 76k+ miles) (MY2015)

Thanks Ian. Andy
Freelander2 HSE (59 Plate, MY10 spec)