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Thread: What causes an intercooler to expand and split guys??

  1. #1
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    Default What causes an intercooler to expand and split guys??

    The intercooler on my vectra 150 cdti has swollen to the point were it has burst at the top and bottom !!
    I noticed it was leaking recently as i could hear it whistling! When i checked it has split along the top and both the top and bottom rows of the intercooler have doubled in size.. Just wondered why this has happened??
    The car has been remapped in the past and is running over standard power but i dont know by how much! I have had it suggested that the increased power might have caused this to happen tho i cant see how as it aint that powerfull me thinks!!!
    Could this be the actually cause of the damage or is there another likely cause known to do this??
    Im thinking it must be caused by some kindof pressure biuld up but im not sure how this is happening!!
    Cheers for any ideas! Dont really want to go buy another standard intercooler if its ganna be bent out of shape again ..

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    Default

    a bit too much boost caused by the remap maybe, do you know where it was mapped?

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    I have no knowledge of what work was done on the car which is a real bummer.
    The guy i bought it from said it was done by the guy before him and he didnt really bother getting the info.
    I do know it seems to boost very well and def doesnt seem standard but not knowing what was done and how means i have no idea how this was achieved!
    Im not even sure if theres a way of finding out what was done to it

    Car has been looked after so im hoping it wasnt bodged in any way!
    If anyone has any ideas on how i can get some clues as to what has been done if would be very helpful but im guessing without the info from who done the work im stuffed!!

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    Full Member Caveman_nige's Avatar
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    I found this info elsewhere..:

    A swollen intercooler is often due to the EGR valve sticking closed, causing both the combustion chamber temp to increase and also the the air into the intercooler. You need to find out why the EGR *may* have stuck closed, it may be just dodgy or maybe the turbo oil seals are wearing, allowing oil to be burned and clogging the valve up.
    My old Signum, the animal; she now rests in pieces in several other members cars.. https://www.vectra-c.com/forum/garag...vehicle&id=200
    The wifes vec show car, started as a standard daily driver and ended up like this. https://www.vectra-c.com/forum/garag...vehicle&id=709



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    Default

    hmm wouldn't blanking & or deleting via remap cause the same problem then

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    Ahh! my motor has the egr valve blanked off and the pipework removed! Strange set up tbh as the guy who did it also removed the management light from the dash somehow The light doesnt show at all
    When i check with reader it shows the fault for faulty egr valve tho!

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    Full Member merikiito's Avatar
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    nice one, looks like he smashed the LED or maybe covered it with tape under the screen
    Lois Griffin: Peter! You're bribing your daughter with a car?
    Peter Griffin: Ah, c'mon, Lois, isn't 'bribe' just another word for 'love'?

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    Yer im guessing it wasnt a proper deal remap as this would of been taken of during the mapping process ( i get a fault code for the circiut of the management light so im guessing its been hacked or something!)..
    Ive noticed she pumps out some black crap when booted aswell so im thinking shes prob over fueling somewhat!
    Would take her in for a class map but ive been qouted around 400 to do that and ive not got that kindof dollar right now tbh!!

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