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