Problems of the intercooler: symptoms, cost and affected models
We have documented 8 faults of the intercooler in 8 engines, affecting 65 models of car in our database. The most important by severity and frequency: premature turbo and intercooler failure (2.2/2.5 dCi), coolant leaks and overheating from the turbo hose (1.0 EcoBoost) and wear of the turbocharger and charge-air intercooler (OM654).
How it works and why it fails
Intercooler and turbo hoses
The intercooler cools the air compressed by the turbo before it enters the engine. Between the turbo, the intercooler and the intake there are hoses and pipes that handle pressure and heat, and they commonly crack or come loose over the years.
What to do
A leak in the intercooler circuit causes a sudden loss of power, makes the turbo whistle and can trigger limp mode. Check clamps and hoses before replacing expensive parts. A lot of oil inside the intercooler points to a turbo problem or a crankcase breather issue.
General explanation by MotorFiable. The specific faults of each engine and car, with their sources, are on the linked pages.
Common symptoms
The symptoms that come up most often in the documented faults of the intercooler. Open each one to see what other faults cause it.
Problems of the intercooler by engine
From most to least important (severity × frequency). Each page details the affected versions and years, symptoms, cost and how to check for it.
- 1High severityFrequency: Common2.2/2.5 dCiPremature turbo and intercooler failureOn the X-Trail with the 136 hp 2.2 dCi, the turbo and its intercooler are the most cited fault: they appear in nearly half of the reliability accounts consulted. On the Primera and Almera, with the same engine, the documented cases are far fewer.
- 2Critical severityFrequency: Occasional1.0 EcoBoostCoolant leaks and overheating from the turbo hoseThere are documented cases of turbo hoses that crack and drain the coolant without warning, which can overheat the engine and even seize it. We have not found a Ford campaign for the 1.0 EcoBoost in Spain; Ford's best-known fire recall concerns a different engine, the 1.6 EcoBoost.
- 3High severityFrequency: OccasionalOM654Wear of the turbocharger and charge-air intercoolerThe OM654's variable-geometry turbocharger and its intercooler can start to fail from around 75,000 km, with loss of power or whistling noises. It is not the engine's most cited fault, but it appears recurrently across several models that use it.Appears at around 74,000 km
- 4High severityFrequency: Occasional1.4 D-4DOil build-up in the intercooler of the 1.4 D-4D (2014 campaign)On the 1.4 D-4D, oil from the crankcase or turbo breather can build up in the intercooler and pass into the intake, with heavy smoke and, in extreme cases, engine damage. Toyota ran a campaign in 2014 for this engine.
- 5Medium severityFrequency: Common1.8 TDCiCracked boost hoses and turbo wearThe boost air hoses on Ford diesels of this era, including the 1.8 TDCi, crack over time and cause a loss of power; the turbo itself can end up damaged if this is not detected in time.Appears at around 35,000 km
- 6Medium severityFrequency: Occasional2.3 MultiJetIntercooler hose coming off the intake throttle bodyOn the 2016 to 2019 Ducato 2.3 Euro 6, the hose connecting the intercooler to the intake throttle body could come off: the engine warning light comes on and power is lost. Fiat corrected it with two recall campaigns that replace the seal or the clamps.
- 7Medium severityFrequency: Occasional2.0 CDTICharge air hose cracked or loose on the 2.0 CDTI in the Insignia AOn the Insignia A 2.0 CDTI, the charge air hose can crack or come off the intercooler: the service reminder comes on, the car loses power and the codes P0299, P2282 or P2458 may be stored.
- 8Low severityFrequency: Rare2.0 TDIHissing when accelerating from damaged hoses or intercooler on the Transporter T6 2.0 TDIOn the Transporter T6 2.0 TDI (2015-2019) a hissing sound can be heard when accelerating, caused by loose or damaged hoses or a crack in the intercooler. Often there is no loss of power and no warning light; oil stains reveal the crack.
Engines with faults of the intercooler
Frequently asked questions
Which engines have the most faults of the intercooler?
By severity and frequency, the 2.2/2.5 dCi (premature turbo and intercooler failure, high severity), the 1.0 EcoBoost (coolant leaks and overheating from the turbo hose, critical severity), the OM654 (wear of the turbocharger and charge-air intercooler, high severity), the 1.4 D-4D (oil build-up in the intercooler of the 1.4 D-4D (2014 campaign), high severity), the 1.8 TDCi (cracked boost hoses and turbo wear, medium severity) and the 2.3 MultiJet (intercooler hose coming off the intake throttle body, medium severity). In total we have documented 8 engines with faults of the intercooler.
What symptoms does a fault of the intercooler cause?
The most frequently cited in the documented faults: turbo whistle or siren noise, gradual loss of power, engine fault warning light (check engine), bluish smoke from the exhaust, coolant loss with no visible leak and overheating or temperature warning light.