CR Cold Weather Inspection intercooler icing

Discussion in 'Mk5 VW Jetta, Sportwagen, and Audi A3 TDI forum' started by dweisel, Nov 19, 2010.

  1. dweisel

    dweisel Member

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    Just wanted to give all CR owners a heads up with cold weather fast approaching. Some CR owners including myself have found water and oily goo in their cold side inter cooler hoses. Its usually not a problem if there isn't much there. At times though this water can build up enough that when it freezes it can casue a no start problem. The inspection of the cold side inter cooler hose is quite easy. First remove the plastic belly pan. After the pan is off look on the right side of the engine from below. You will see a rubber hose approx. 2 inches in diameter. This is the cold side inter cooler hose. On one end of the hose you will see a regular hose clamp. On the other end is a band type clamp. The end with the regular hose clamp is the end you want to take loose. This end connect to a plastic duct. Loosen the clamp enough to slide it back on the hose out of the way. Now work the hose off the plactic duct. It may take a little effort as it does fit tightly. As soon as you get the hose started off you may get some water from the hose. Pull the hose completely off the duct. This will let you drain all the water(if any) There may also be some oily goo. This goo is from normal oil and water/dirt mixing together in the hose.The color of this goo can range from dark gray to tan. Various amounts of water have been found by owners. On my 09 JSW I removed approx. 1-1/2 to 2 cups. On my 09 Sedan the water was minimal. I checked my neighbors 09 Sedan and the water was also minimal in her inner cooler hose.

    dweisel
    LUBRICITY,LUBRICITY,LUBRICITY!

    Here are a few pics of what you may or may not find.

    [​IMG]

    [​IMG]
    Last edited by a moderator: May 29, 2011
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  2. chittychittybangbang

    chittychittybangbang Administrator

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    Yuck! Why is there so much condensation in there? I always wear gloves when handling chemicals like oil and such. That looks pretty nasty.

    Also, for anyone who does remove the hose, make sure that it's clipped on properly or else it can pop off later when you're driving and cause a running problem.
  3. dweisel

    dweisel Member

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    Chitty, I don't think that much water was caused by condensation in the inner cooler. Our JSW was run in 10 hours of steady hard rain. My thoughts are the water could have been pulled in through the upper hose clamp by a difference in the pressure between the outside and inside air. Other people have found this same water in their inner cooler hoses. Some have found even more than what I did. One case I know of the entire hose was blocked off with solid ice and caused a no start problem. IIRC, there was someone else who's hose had enough water in it that it was injested into the engine. So, I feel its a good thing to keep a check on periodically,especially in wet conditions. The oily goo looks nastier than it really is. I hope other members check their cold side inner cooler hose and report back their findings.

    dweisel
  4. D-Cell_Mekanick

    D-Cell_Mekanick Member

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    James I'm sure you have followed the latest "2009 Jetta major engine failure. Your thought please." Thread over at the place that banned you. I'm sure if you where to speak to the Mods you may be able to get this info transfered over there.
  5. dweisel

    dweisel Member

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    I'm not really interested in going back and posting on the tdiclub anymore. Too much censorship by the mods and its not worth the hassle. As far as the thread you are asking about. I can't view the tdiclub anymore even as a guest. They are pretty throrough at blocking ALL my devices. Home pc,laptop and phone.

    dweisel
  6. D-Cell_Mekanick

    D-Cell_Mekanick Member

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    Wow, I didn't know it went that far. Sorry bout that, I didn't know they could block you from viewing the forum.
  7. dweisel

    dweisel Member

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    They just have my ISP addresses blocked. I could use another device if I really wanted to view the forum. My ban at tdiclub will be lifted at 2am 01/02/2011. I'll probably check in and see whats going on,but I doubt I'll start any threads or post anymore. Of course ''Never say never'' so, I won't say I'd never post there again.

    dweisel
  8. chittychittybangbang

    chittychittybangbang Administrator

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    Sorry to hear that...you have really good info and I don't ban anyone unless it's spam or a flagrant violation of the rules.
  9. dweisel

    dweisel Member

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    Thanks Chitty,its way different here. Now back on topic. CR owners please check your cold side inner cooler hose. I think its a good preventive maintenance thing to do for anyone running in cold wet weather.

    http://forums.tdiclub.com/showthread.php?t=302863

    dweisel
  10. DWalk

    DWalk New Member

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    Thanks dweisel, good to see you have found a new place to post your information.

    Chitty, perhaps you could expand on dweisel's description of checking the inter cooler hose and put it in the "how to" section of your website. Just a thought...

    BTW, your "how to" section is awesome and so easy to navigate!
  11. chittychittybangbang

    chittychittybangbang Administrator

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    Thanks for the suggestion, I have added a link to this thread and dweisel's pic to the buying guides.
  12. 6eggs

    6eggs New Member

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    Is this a problem on just the CRD engines?
  13. freeflyer

    freeflyer Member

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    and my IC hose is clogged too

    just got back from my 45k inspection and of course they found the sludge in my IC hose as well. The 'mechanic took the whole intake side apart and cleaned everything. His 'quick and dirty' solution is to remove the L shaped hose between the air filter and the intake box (see pictures). He thinks I get warmer air so there would be less moisture. He also confirmed that the problem is known amongst the VW dealer at least here in Montreal, but he stated that VW has no solution to this yet.
    So what do you guys think about this quick fix??????

    Attached Files:

  14. bruce846

    bruce846 New Member

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  15. chittychittybangbang

    chittychittybangbang Administrator

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    If it's anything like the older filters, my guess is that the warm filter is a paper element. The cold filter is the same paper element with a foam element over it.
  16. bruce846

    bruce846 New Member

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    ... and the foam performs what task?
  17. n1das

    n1das New Member

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  18. n1das

    n1das New Member

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    It's only been an issue on the CR TDIs. The thinking in the TDIclub thread I posted a link to is that the low-pressure EGR circuit injects steamy exhaust into the intake ahead of the intercooler and into air that's already saturated with moisture. This is not an issue in older TDIs because of no low-pressure EGR system due to no exhaust aftertreatment systems like what the CR TDI engines have.

    I've noticed the exhaust from my 2010 JSW TDI is more steamy during warmup compared to my older TDIs. I like to not waste time with warmup to help minimize the amount of steamy exhaust being introduced into the intake ahead of the intercooler. In the cold weather, I start it up and GO as recommended and don't wait for any warmup.
  19. freeflyer

    freeflyer Member

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    Again!!!!!!!!!!!!

    See post 13 for the first incident... yesterday 0600am on the highway form Montreal to Ottawa I suddenly lost power and got the glow plug light and the check engine light at the same time. After an hour of waiting for the Tow Truck the engine came on again without any warning lights (???) werd
    Got towed anyway to the next VW dealer where the found an ice plug in the intercooler hose as described so many times in many posts in many different forums. The dealer keeps the car until this evening. They said: Everything is cleaned and thawed (!!) and there is no solution to the problem. They even put that elbow joint back to its place.

    They stated that next time I could just wait in the car and continue my journey once the car runs again... (What????!!) :BS


    I drive this every day and I need a reliable (and fuel efficient) ride. VW get your act together!! This is unacceptable! One more time I get stuck on the highway with -15° C OAT and I will see the CAMVAP.
  20. Corpsman

    Corpsman New Member

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