MK5 GTI - Intercooler Hoses leaking again. Replacement suggestions please.

[GreigC]

Today I had the car serviced and hand-break cables replaced. My mechanic said my intercooler pipes are leaking again (only the drivers side) I’ve changed all the O-Rings twice now on both cooler pipes over the last 18months. I bought all Genuine seals and replaced the correct part numbers to the correct sides as one side is bigger than the other… I want to change both intercooler pipes and keep the original OEM intercooler. If I buy genuine I believe there is a cross over in part numbers depending on year. My Car is 2009 MK5 GTI. I would also consider aftermarket if recommended.

Thanks

[mjmallia]

Fit the S3 / Mk6 R intercooler which is larger and does away with those leaky joints. Loads of info online and did it to mine.

[ZoliWorks]

Yeah, straight up replace your mk5 intercooler with the next one. No matter what you do, those quick connections are going to leak regardless.

[GreigC]

So if I remove the MK5 cooler and get a MK6 cooler from an R or 8P S3 cooler what about the hoses.. what’s involved with those?

[mjmallia]

Use original hoses, but the cooler ends need the metal outer ring cut (carfully) and removed to create a simple hose connection.

Add a hose clamp and you are done.

[mjmallia]

This is the later PN number with the plastic end tanks and more efficient core, than the early solid end tanks.

It comes on the S3 8P, Mk6 R, and also the Sirocco R TSI which is where mine came from.

[GreigC]

Ah I see, so you keep the original pipes and cut the ends and use jubilee clips?

[mjmallia]

Yep

[GreigC]

Just to double check the above intercooler is just a direct swap? Nothing else needed? Found one on eBay I might purchase.

[mjmallia]

Direct swap.......front end of car off though

[GreigC]

Thanks mate.

https://www.ebay.co.uk/itm/135501503598?mkcid=16&mkevt=1&mkrid=711-127632-2357-0&ssspo=dmejPXOuSCS&sssrc=4429486&ssuid=fNXbuBooTum&var=&widget_ver=artemis&media=COPY

The hoses supplied with this work on the MK5 GTI or do I still need to cut my originals?

Cheers

[mjmallia]

That BE version is an early revised part from the older alloy end tanks..........as the BP like what I have,  replaced it for whatever reason and is the current part num I believe.........not sure what they changed to improve it.

Otherwise is should work.........you will still have your originals and can mod them to fit without issue.

Also look for the rad packs, as they sometimes come cheaper or the same price.  I bought mine for £100 off a Sirocco R 2.0 TSI  and have a newer fan pack, rad and connecting parts as spares ..........easily sellable as the fans can get £100 on their own..........also coming like that protects the intercooler come delivery as it is sandwiched.

[GreigC]

Thanks for all your help so far on all reply’s.

I’ve bought the intercooler above from eBay (Genuine Audi TTS (2011) intercooler 1K0145803BE) I’ve been told from my mechanic that the discharge pipe is also leaking and dripping onto the under-tray…If the discharge pipe is at fault… What discharge pipe will work with the GTI KO3 turbo and TTS intercooler I’ve purchased? I’ve already changed the seals on the OEM discharge pipe… but I think the factory hoses to the discharge pipe to the intercooler have worn (metal ridges) hence the leakage…

Is there a pipe that goes from the intercooler I’ve bought to the discharge pipe that uses jubilee clips on both sides instead? or can I use the pipes that came with the TT intercooler to the factory MK5 GTI discharge pipe? (8J0-145-832-A) Thanks

Image below of the TT hose.

[ZoliWorks]

Yeah that specific area gets worn out the most. There's no fix, other than going with an aftermarket discharge pipe. I bought one of those cheap ebay discharge pipe kits, cut off the part where you put the quick connect port, welded an aluminium tube to extend it and tightened my intercooler rubber hose with a collar onto it.

[GreigC]

 

Yeah that specific area gets worn out the most. There's no fix, other than going with an aftermarket discharge pipe. I bought one of those cheap ebay discharge pipe kits, cut off the part where you put the quick connect port, welded an aluminium tube to extend it and tightened my intercooler rubber hose with a collar onto it.

Thank you for the info Looking at this…

https://www.ebay.co.uk/itm/182556277313?var=0&mkevt=1&mkcid=1&mkrid=710-53481-19255-0&campid=5338749392&toolid=20006&_ul=GB&customid=EAIaIQobChMI_6yJ9JTOiwMV_pRQBh26TQxvEAQYASABEgLwS_D_BwE%7C0AAAAADihhqX12KlkWBgMKApIodntutEyj%7CCj4KCAiA2cu9BhBTEi4Aad609L2ZAr3FcSKLhh5-TJjoFmUbov7z84FV5pXSuGOvr8BPxIqrraXCz-gwGgKORw&gclid=EAIaIQobChMI_6yJ9JTOiwMV_pRQBh26TQxvEAQYASABEgLwS_D_BwE&gbraid=0AAAAADihhqX12KlkWBgMKApIodntutEyj&wbraid=Cj4KCAiA2cu9BhBTEi4Aad609L2ZAr3FcSKLhh5-TJjoFmUbov7z84FV5pXSuGOvr8BPxIqrraXCz-gwGgKORw&gad_source=1&gbraid=0AAAAADihhqX12KlkWBgMKApIodntutEyj

if I cut the metal end off my factory intercooler pipe (both ends) do you think it would fit over the modified pipe? Or would I need different pipes.






I asked the fabricator he said this.