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-   -   Drilling a drain hole in the intercooler plumbing (http://forums.tdiclub.com/showthread.php?t=431560)

2011tdiproject January 1st, 2015 20:03

Drilling a drain hole in the intercooler plumbing
 
$2 is the cost of the drill bit to do this mod. I'm guessing all it's going to take to fix the intercooler icing/water hydrolocking problem is drilling a pinhole at the lowest point of the system. That's what we did with my dad's Volvo, after we drained about a glass of water out of the intercooler.

Anyone do this yet?

I am not going to read the entire 100+ page thread on that. I felt like banging my head into a wall after only about 10 pages, so much completely incorrect info and complaining with no solutions.

I will probably do this on my car soon, as it's done the hard start thing twice now. Crank crank fire then sputter sputter stall. Crank crank crank dead. Like a dead battery. Can't crank anymore. Wait. Crank crank sputter sputter, 2 cylinder idle, even when revved, still on 2 cylinders, then cleans up. Last time it wouldn't fire, but it would still crank. Just held the starter on waiting for it to clear out. Ugh. Don't want to bend the rods.

Most people probably think this is gelled fuel/weak battery, or fuel gelling in the HPFP making it hard to crank, but it's not, I know that now. It's the motor inhaling water melted in the intercooler after sitting. With a pinhole, the water *should drain out. It does with my dad's Volvo.

I'll link or post video/pics of this later..

opinionated January 2nd, 2015 04:06

I wouldn't drill a hole in the intercooler no matter how small it is.

The intercooler is AFTER the turbo, i.e. under boost/pressure. Drilling a hole will cause you to loose boost, therefore power and efficiency.

elitegunslinger January 2nd, 2015 05:05

If you plug it back up, sure why not. :D

There's a thread where someone made a hook for this exact purpose; did wasn't a hole but it allowed you to drain the intercooler... Let me have a look around.

Found it:
Quote:

Originally Posted by 2micron (Post 4078703)


2011tdiproject January 2nd, 2015 11:08

Quote:

Originally Posted by CjGaughan (Post 4702319)
I wouldn't drill a hole in the intercooler no matter how small it is.

The intercooler is AFTER the turbo, i.e. under boost/pressure. Drilling a hole will cause you to loose boost, therefore power and efficiency.


Real world, correctly sized hole, the amount of boost you'd lose is not really measurable.

Windex January 2nd, 2015 11:40

I would think that a small hole would whistle under boost - that would be a annoying.

I would be more inclined to use something like the pull-valves on truck air tanks:

http://www.bnbinternational.com/site...alve_thick.png

You would just need to route the pull cable somewhere you could access.

I think there would be enough positive pressure in the intake tract idling to force out any water, as long as it isn't frozen.

2011tdiproject January 2nd, 2015 12:13

I'm talking about a hole like under 1/32", really small. The idea of 2micon's kit and the valve itself is legitimate, I just want to keep it as simple as possible, and have it work on its own. I don't want to engineer a "VW like" solution, in other words!
As I said, this worked on my dad's car, so I'm hoping it will on the tdi.

Ol'Rattler January 2nd, 2015 14:02

Would probably work fine. The amount of boost you would loose would be small. Just make sure the hole is at the lowest point of the charge air pipe.

ATR January 2nd, 2015 19:12

Of coarse you could always plug the hole with a rubber insert or a small screw...

2011tdiproject January 2nd, 2015 21:09

This is how much water poured out of the hose going up to the intake manifold. Not much. The driver's side hose had no water at all.

http://i60.tinypic.com/4jnj2p.jpg

This is the intercooler side of the hose going up to the intake. relatively clean, not too bad inside. 68k miles.
http://i59.tinypic.com/ics182.jpg

And here is the very small hole I drilled. I thought I had all the water out, but as soon as I pulled the drill bit out, drip drip drip drip drip

Should work fine.

http://i58.tinypic.com/1qmv6q.jpg

http://i57.tinypic.com/2rnitkp.jpg

And, since I already had the car on the lift, I figured I might as well pressure wash the underside and spray it with gear oil to keep the road salt in check. Damn pressure washer tore the protective rubber right off a little section of my parking brake cable, so I threw some liquid electric tape on it.

VeeDubTDI January 2nd, 2015 21:58

As for the tiny hole drilling mod, it will allow the water to drain, until the sludge clogs up your hole. Then the sludge will build up, along with water that can't drain out, and you'll have to take it apart and clean it. At least, that's my prediction.

The sludge that I'm referring to is the emulsion of water (from the condensate) and oil (from the crank case vent).

2011tdiproject January 2nd, 2015 23:19

Whoever took my thread and put it here, thanks, now I'm considering quitting this forum. No one wants to sift through 100+ pages of this, you've basically taken my info and thrown it away. You want to do something right? Take out 99% of this worthless thread and distill it down to something worthwhile. Otherwise, leave my threads alone.

b1jackson January 3rd, 2015 03:27

Chill out. You drilled a hole.

flyboy320 January 3rd, 2015 04:36

Quote:

Originally Posted by 2011tdiproject (Post 4703163)
Check out my thread $2 intercooler water/ice fix, I just did it tonight, but I bet it'll work..

So is this hose under pressure or vacuum when the cars running?

Samcar222 January 3rd, 2015 07:05

Nice job, looks good. I recently pulled my cold side hose after two hours of highway driving in 20-25*f weather, while running both the upper and lower IDparts grille blocks (I also have the IC tsb installed). Some goo, but no water. Let us know how this hole mod works! Did you drill a small hole in the plastic belly pan too?

Ppolaris1010 January 3rd, 2015 13:47

Quote:

Originally Posted by 2011tdiproject (Post 4703213)
Whoever took my thread and put it here, thanks, now I'm considering quitting this forum. No one wants to sift through 100+ pages of this, you've basically taken my info and thrown it away. You want to do something right? Take out 99% of this worthless thread and distill it down to something worthwhile. Otherwise, leave my threads alone.


X2 how are questions supposed to be answered when you put them in this way to long tread


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