DIY: How to replace intercoolers on a 3.0T Audi S4 (S5, A6, A7, Q5, SQ5)
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- Опубліковано 26 лип 2024
- DIY on how to change your intercoolers on an Audi S4 which has the 3.0T engine. Common problems of an intercooler leak is a slow coolant leak that you cannot find externally. Miss fire on a cylinder that has been replaced with a new coil pack and spark plug, that you have no other Idea why else it would be failing. Clean metal on the inside of the intercooler and dried coolant on the supercharger.
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Video Breakdown:
0:00 Intro
0:32 Tools you will need to complete job
1:15 How to take off throttle body
2:36 How to take off rear bolts of intercooler
2:59 How to take off metal shroud in the rear
3:34 How to take off front water pipe
4:12 How to take off the intercooler safely from the supercharger
6:50 Insepection of intecoolers
7:48 How to install o ring on water pipe
8:54 How to install front supercharger gaskets/intercooler
9:59 Installing the intercooler safely (Must do prior step)
12:50 How to reinstall metal shroud
13:14 How to reinstall throttle body
14:12 How to reinstall front water pipe
15:10 How to bleed intercoolers ( Must do this to prevent damage to new inercoolers)
Torque Specs: (Nm= Newton meters)
Intercooler bolts: 9Nm
Throttle body bolts: 10Nm
Water pipe bolts: 9Nm
IF YOU ARE ONLY DOING A INSPECTION ON THE INTERCOOLERS YOU ONLY NEED THESE PARTS
Intercooler gasket front for supercharger x2 : 06E-145-723-E
Intercooler gasket rear for intercooler x2: 06E-145-723-A
List of items needed to change replace intercoolers
Intercoolers x2 : 06E-145-621-S (Rear Gasker is included)
Intercooler gasket front for supercharger x2 : 06E-145-723-E
Water pipe O rings x4 : 06E-121-119-D
Link for cheap parts down at the bottom
List of mods
Cosmetic:
RS Grill
Window tints
Chrome delete and roof wrap
Black mirror caps
Merc Racing heater exchanger (HX)
Performance:
034 Track density motor mounts
034 Rear Sway bar and Sway bar end links
034 190mm Crank Pulley
Integrated Engineering Cold Air Intake (IE)
Integrated Engineering Stage 2 tune and DSG
Links:
Intercoolers: ( I know it says volkswagen but trust me its Audi)
www.vwdirectautoparts.com/oem...
Water pip o Ring:
ecstuning.com/b-victor-reinz-parts/sealing-o-ring-priced-each/06e121119d~vic/?gclid=CjwKCAjw4_H6BRALEiwAvgfzq08LuTp6fhO-vcbX-5y8H1J16FWcCZeB3ftSQashgnbcTvniv49yMxoCjm8QAvD_BwE
Intercooler gasket front of supercharger:
www.ecstuning.com/b-genuine-v...
DISCLAIMER
I am not responsible for anything that may happen to your car. - Авто та транспорт
Always lubricate your O rings with silicone grease!
I guess im randomly asking but does anyone know a way to log back into an Instagram account??
I was dumb lost the password. I appreciate any assistance you can offer me
@Yahir Noah instablaster ;)
Incorrect. The intercooler seals you are to use engine oil not silicone. Never use silicone based products within the intake system.
Agreed. My GF keeps telling me that over and over and over again... Just saying.
Offering feedback as you requested at end of video. I have performed this task twice and fairly strait forward per your video. A couple of call outs: when installing intercoolers lubricate seals/O-rings with motor oil, including the long rubber seal that is parallel to intercooler (essentially all rubber contact points should be lubricated with motor oil for installation). Not doing so you risk damaging seals as there is too much friction, that is why you struggled installing intercool. Audi service manual stresses this lubrication of seals during install. Also, I cringed when you used a screw driver to pry the intercooler loose. That is a machined surface and you don't want to damage it. I found a small wooden block between intercooler (at water pipe end) and hammer works quite well.
If you don't have the tool to properly fill coolant system and you find yourself purging air, then there is a third bleed location at the firewall. You will find the passenger side heater core hose at the firewall has a hole in it. This too is a location to bleed air from the cooling system. Work the hose back until hole is exposed and coolant flows out.
Otherwise, I admire your attempt at replacing supercharger intercoolers. Most folks would be intimidated. Also, intercooler was aged but I noticed the last character in p/n was an 'F'. Audi has revised these intercoolers many times over with current revision ending with an 'S' character (which you installed). Early intercoolers are known to fail with small coolant leaks, typically leading to loss of coolant but, no indications of it and/or a cylinder misfire.
Great feedback! I think I did say in the video you should lubricate the o rings but I didn’t do it as a step. That is good to know, I do now have silicone grease and assembly lube. Also, I see your point on the intercoolers, I knew it was bad so I didn’t care if I damaged mine. It seems like everything Audi made had revisions to it
Thanks for the video.
Just finished this service on my A6 C7, and flush oil, it was dark brown and smelly...also cleaned valves and found a small coolant leak ( thermostat pipe, someone replaced it before and didn’t installed it correctly).
Been trying to track down an invisible coolant leak in my 3.0T for a little while now and I just threw a cyl 3 misfire code today. Going to pull the plug soon to see if its fouled with coolant and I have a feeling I will be doing this process very soon. Im stoked to have come across such a well documented and thorough video on the process. Thank you very much. This video has made me confident I will be able to do the job myself!
If you need help ask Audizine
Pretty sure thats Tstat
@@blondishasp572 ended up being the IC cores and PCV. Wound up doing WP, tstat along with it tho.
Nice work!. Thanks for posting. Liked and Subbed
Thanks for the sub!
Great video !
A couple tips, lay something flat against the front of the IC when removing and hit it with a 5lb dead blow. Then once it starts to move I turn it and use the handle to push it the remaining way out. Then when installing push it with your hand most of the way until the front starts to seat, then you can start putting your bolts in and then as you tighten those it will seat it the remainder of the way. Also another subject you might want to note is its VERY common for these intercoolers to arrive with the flange side slightly bent back , which leads to a very small boost leak between the flange and the gasket. I now just to be sure take a flat head or punch and tap around the edges once you seat it with your hand to bend it slightly toward the gasket, prior to starting to bolt them in. I have had zero issue since I started doing this on them.
Mike @ Mad By Design
I was thinking of sending my SC to you for a port, might have to do that in the future.
Nice video man .. got a new subscriber here
Thanks for the sub!
When reinstalling, no need to use a mallet, Just push by hand and tap it in with your palm, shouldnt be an issue if you lube the side seals and o'ring. another video the guy has the audi manual and they recommend highly that no tools be used to force it in. I had no issue using my palm for reinstall. Dissassembly is a little different though. You will bend them if you use a mallet. I would recommend cutting a circular piece of something and drilling holes then screw it in at the end to remove them if you're gonna reuse them to prevent bending in the intercooler. once there bent, it is very difficult to reshape them flat again. I was reusing 1 of 2 and had a small bent and was able to use a bolt with a washer to try and force it back out flat. I don't know yet if it will leak or not.
yuhhhhh🐐
I know you pressurized and bled the coolant from the super charger did you bleed it from the heater core section aswell? I know air can get stuck there or does pressurizing it not
Do I also have to bleed the heater core or is the supercharger just fine, i’m doing a direct swap out supercharger
You got a link to that coolant vacuum pump?
Great video! I am gradually losing coolant when I drive (S4) with no visible external leaks. No misfires, no codes but do have some white smoke from exhaust, not a lot. A pressure test on coolant system held 1 bar solid for 45 minutes, so it's not clear what's wrong. Most recommend to swap out to he pcv, so I'm going for that first. Will come back to supercharger intercoolers if still a problem, although would expect to have lost pressure on the test if they were leaking.
If you can, try testing the oil cooler or the stock heater exchanger. This would be the cheapest and easiest parts to get to
Been there done that. When your replacing pcv/oil separator the supercharger is off. Perform a thorough inspection of intercoolers and intakes for signs of coolant sludge. It will be a milky brown residue.
I had a fair amount of coolant loss with no smoke, noticeable leaks etc, but I could smell it. It ended up being the PCV and the coolant was burning off in the block valley before it could visibly leak.
I had one leaking maybe for the past few years as the coolant would drop a little over a year and was topped up with the oil changes once year. Audi is replacing both of them and doing carbon cleaning too on my low mileage tuned 2010 S4.
You got lucky
@@quattrogang63 Not free. Paid 3200 before tax and the carbon cleaning was half price at about 660 in that amount.
@@paull3179 oh man, I would of paid a independent mechanic or a 3rd party shop. That’s a lot of money
@@quattrogang63 my independent Porsche specialists costs about the same and no discounts. At Audi I get 15% off parts and labour while the other shop laughs if I ask for a discount. My full brake job was quoted for less than the other shop and plus it is worth paying for high quality work. I charge more than the dealer for my time.
@@quattrogang63 I take my 991S to the Porsche specialist but they are expensive. I like having a new loaner which only dealers will provide so I am thinking of using the porsche dealer in the future.
Awesome video man! Question, what was the mileage on your car when you did this work? I love my S4 and know about the common issues thanks to ShopDap - Thermostat, PCV, engine mounts, etc (All around 50k). Trying to budget for major work at ‘common failure’ intervals.
This failed at around 85k miles with a tune. I think if you're not tuned it wont fail but, if you are it might fail prematurely
@@quattrogang63 Thank you. I have a 2016 Stage2 Dual pulley with APR CPS system. I don't race or track the car - cruise around town with the kids and mash on it once or twice a ride to put a smile on my face (and the kids)
@@markjohnson2079 what a fun family car
@@quattrogang63 that's exactly the mileage point when mine failed as well.
@@quattrogang63 6 month update - leaking fluid into Cyl3. So - failed at 44k miles. Not fantastic. I appreciate the video even more now!
Hey man ,thanks for the video. Can u pls give me the name for the pump and adaptor u used to pressurise the system?
The pump was from snap on. You can use any type of pump with the right threading. Just pour in coolant first and pressurize it after
Instead of hitting it with a hammer u can over torque the bolts in a star pattern and it will fall into place
Nice! Are you in New Jersey?
Nope, on the west coast
Ask for John @ JA Autoworks Shrewsbury nj. Best Audi vw service tech i know outside of dealers @ reasonable rates.
Do the new OE intercoolers come with both front/back gaskets included, or do you need to purchase these as well?
Only the back gaskets. I explained that in my video. You have to buy the front ones. I linked the part in my video and description
How do I know if it’s bad and when do they go bad?
You lose pressure when you pressure test your coolant and cannot find any leaks that are visible. Also, you have a miss fire that is ruled out from a spark plug and coils.
why did you pressure bleed the system instead of just putting the whole system in vacuum ?
Didn't have the right fitting for the vacuum system
Question, how do you know it failed? Does the car pop up a code?
It does, but with earlier revisions of the intercooler it might not.
Intermittently rough idle and cylinder misfire codes (EPC light) are what I'm experiencing. I'll be doing this same service soon.
Doesn't look like a very efficient design compared to a front mount or top mount, where cooler air is forced onto the intercooler. Looks like a lot of heat soaking with this design unless I'm looking at it wrong.
🍤
Did you have any white smoke coming from your exhaust when it leaked?
No, I did not, I would have violent miss fires on my engine though. If enough coolant gets into the combustion chamber I would think you would see white smoke
@@quattrogang63 that’s what happened to me. Misfires and then white smoke a bit later on
@@S54VR6 Check your Spark plugs and Ignition coils. You could have a head gasket leak. Do a cylinder leak down test on the cylinders that are miss firing also, get some block test fluid and test the block. If your car fails one of these tests you will have more insight into what is wrong with your car.
@@quattrogang63 appreciate the input! I tore down the supercharger and found bank one intercooler was leaking into cylinder 3. Just waiting on parts now but I’m praying that’s what it was
@@S54VR6 You might want to get a Map sensor for that bank, I had to replace mine
Why? Just upgrade it. They suck
I didn't have that option at that time, upgrades are not that easy to come by