Engine: D5: - S 60 Leaking Intercooler

Haystacks · Oct 26th, 2009, 12:27

I've been told that the intercooler is leaking on my S60. It's the one that cools the air going into the engine. Can they be fixed/repaired? Are they expensive to repace?

Can anyone tell me what the actual problem is? I thought the turbo intercooler cools the air that enters the engine. If this is leaking surly this means there will be an increase in temperature of the air entering the engine. The bigger the leak, the more 'uncooled air' is taken in. There seems to be some oil leakage but I'm not sure how that is relevant to this issue.

How many intercoolers are there on this car?

Thanks in advance for any help.

mbren30 · Oct 26th, 2009, 12:45

Quote:

Originally Posted by Haystacks

I've been told that the intercooler is leaking on my S60. It's the one that cools the air going into the engine. Can they be fixed/repaired? Are they expensive to repace?

Can anyone tell me what the actual problem is? I thought the turbo intercooler cools the air that enters the engine. If this is leaking surly this means there will be an increase in temperature of the air entering the engine. The bigger the leak, the more 'uncooled air' is taken in. There seems to be some oil leakage but I'm not sure how that is relevant to this issue.

How many intercoolers are there on this car?

Thanks in advance for any help.

Hi there,

Funny you should ask this question as i have the exact same problem, mine is going into the garage to be sorted on friday. There is only one intercooler onthe car and yes they can be replaced, albeit at a cost! Mine is going in for 92k service £240, and a new intercooler £440. There is a possibility i might ned my rear brakes doing too as the garage has a note on the system from when it was previously owned that the last time they worked on it the rear brakes were questionable.

Symptoms of a blown intercooler im led to believe is a whistleing sound under hard acceleration and a lot of black smoke from the exhaust. My car is suffering from a screeching sound and a sucking of air sound as i decelerate, i have also noticed a massive loss of power.

Hope that helps

andtal · Oct 26th, 2009, 12:49

Quote:

Originally Posted by mbren30

and a new intercooler £440.

I paid around £400 a couple of years back for mine to be replaced. Pricey, but unavoidable.

My engines still a bit 'windy' so i might get the local spanner man to check for leaks. I opened up the engine bay at the weekend and closed it again, wouldnt know where to start in there!!!!

Good luck.

zx6rman_uk · Oct 26th, 2009, 12:56

Hi,

Right the intercooler,, and Ive replaced 2 on mine..

Yes the intercooler does cool the air that goes into the engine. Now if it leaks the main problem is that some of the pressure thats created by the turbo escapes.

This will equal less power and in my case smoke from the back of the car (less air to fuel ratio I guess)

I went and found a 2nd hand one which wasnt easy as they are common parts to go.

They tend to 'bellow' out at the bottom of the intercooler, and doesnt look fixable. Still cant believe that Volvo can make a intercooler that cant handle to pressuer the turbo wants to put through it.

The one i did get cost £80 and took an hour to fix with the help of the brother-in-law.

Haystacks · Oct 26th, 2009, 13:45

Thanks for this info.

Does the problem show up by oil deposits at the bottom of the intercooler? If so, why?

zx6rman_uk · Oct 26th, 2009, 14:06

Quote:

Originally Posted by Haystacks

Thanks for this info.

Does the problem show up by oil deposits at the bottom of the intercooler? If so, why?

Yes you could see that aswell,, theres a bit of oil that comes from the turbo.

The turbo has an oil feed to lubricate it, and thats what you see when you see the oil.

You will find that the pipes etc have a thin coating of oil on the insode of them

andtal · Oct 26th, 2009, 15:20

Quote:

Originally Posted by zx6rman_uk

oil on the insode of them

you even spell with a black country accent!!

Georgey dee · Oct 26th, 2009, 15:47

I stuck a boost gauge on the outlet of my intercooler to indicate when not if it fails.

Not a job for the faint hearted though. It was a pain in the arse to get working but I started to take it personally so I stuck with it.

Where did you notice the oil? Was it dripping onto the driveway? I'm not sure on diesels but the petrol intercoolers have a small hole in the bottom of them to allow the oil residue to drain off. This is a controlled leak that the ECU knows about.

I would say that if you have lots of oil on the floor and lots of black smoke on acceleration and all of your big bore pipes are intact then your cooler is shot

zx6rman_uk · Oct 26th, 2009, 16:26

Quote:

Originally Posted by andtal

you even spell with a black country accent!!

lol, hadnt noticed my spellin mistake.

andtal · Oct 27th, 2009, 12:33

Quote:

Originally Posted by zx6rman_uk

lol, hadnt noticed my spellin mistake.

in brummie its spelt 'insoid'.

Oct 26th, 2009, 12:27	#1
Haystacks New Member Last Online: Oct 26th, 2009 13:51 Join Date: Oct 2009 Location: London	S 60 Leaking Intercooler I've been told that the intercooler is leaking on my S60. It's the one that cools the air going into the engine. Can they be fixed/repaired? Are they expensive to repace? Can anyone tell me what the actual problem is? I thought the turbo intercooler cools the air that enters the engine. If this is leaking surly this means there will be an increase in temperature of the air entering the engine. The bigger the leak, the more 'uncooled air' is taken in. There seems to be some oil leakage but I'm not sure how that is relevant to this issue. How many intercoolers are there on this car? Thanks in advance for any help.

Oct 26th, 2009, 12:56	#4
zx6rman_uk S60 D5 Owner Last Online: Aug 6th, 2010 13:11 Join Date: Aug 2008 Location: Dudley	Hi, Right the intercooler,, and Ive replaced 2 on mine.. Yes the intercooler does cool the air that goes into the engine. Now if it leaks the main problem is that some of the pressure thats created by the turbo escapes. This will equal less power and in my case smoke from the back of the car (less air to fuel ratio I guess) I went and found a 2nd hand one which wasnt easy as they are common parts to go. They tend to 'bellow' out at the bottom of the intercooler, and doesnt look fixable. Still cant believe that Volvo can make a intercooler that cant handle to pressuer the turbo wants to put through it. The one i did get cost £80 and took an hour to fix with the help of the brother-in-law. __________________ 2003 S60 D5 SE

Oct 26th, 2009, 15:47	#8
Georgey dee Premier Member Last Online: May 1st, 2024 06:21 Join Date: Dec 2005 Location: Norwich View Photos By: Georgey dee	I stuck a boost gauge on the outlet of my intercooler to indicate when not if it fails. Not a job for the faint hearted though. It was a pain in the arse to get working but I started to take it personally so I stuck with it. Where did you notice the oil? Was it dripping onto the driveway? I'm not sure on diesels but the petrol intercoolers have a small hole in the bottom of them to allow the oil residue to drain off. This is a controlled leak that the ECU knows about. I would say that if you have lots of oil on the floor and lots of black smoke on acceleration and all of your big bore pipes are intact then your cooler is shot __________________ HAD; 440 GLT(Loved it), 850 GLT auto(Loved it), S70 2.5T(Nothing but problems!), 850R auto(Loved it!!), S60 D5 SE (Nothing but problems!) GOT; S60 D5 SE Lux Auto RAF Marham Track Day Co-Ord'

Oct 26th, 2009, 13:45	#5
Haystacks New Member Last Online: Oct 26th, 2009 13:51 Join Date: Oct 2009 Location: London	Thanks for this info. Does the problem show up by oil deposits at the bottom of the intercooler? If so, why?

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