intercooler issues.

[Jeff le Gascon]

Hello, it would seem, after quite a few hours of scouring the usual suspects: ebay, parts suppliers, breakers etc; that i'm not going to find an intercooler for my KJ 2007 crd anywhere.

I've taken it to a "radiator specialist" who claims it is dead and irreparable, (same as the turbo salesman told me about the turbo too), which i struggle to believe as it is a basic bit of kit.

Does anyone have any advice?

all the best,
Jeff

 

[Turboman280]

Find better repairmen would be the first advice. We live in a throw away world now, but someone out there still has the skill to do these.

Beyond that, the breaker/wrecking yard is probably your best bet. There are some I found on Ebay but they are asking a good percentage of the vehicle's value ($700-$800 US).

A google search found me Modine 3233871, which seems to be out of production but I found one here. https://isotigers.com/en/home/6120-intercooler-suitable-for-jeep-je512427-3233871.html

I have no affiliation or experience with that site, just found it searching for the Modine number. Happy hunting!

 

[Jeff le Gascon]

Hi Turboman, thanks for the link, waiting for photos to confirm. I thought i found one in a breakers in spain, but it has different mountings. There seem to be so many different intercoolers for the "same" model jeep.
You're right about the repairmen, hard to find these days. I've only been driving cars (not fixing them) for the last 35 years, I can't believe what they've done to new cars since.
I'm rethinking this, I think I can condemn the bottom tube. If I cut away the fins and take out the bottom (completely rotten) tube and cut small rectangles of galvanized alu, I should be able to jbweld it in.

Any thoughts?

Find better repairmen would be the first advice. We live in a throw away world now, but someone out there still has the skill to do these.

Beyond that, the breaker/wrecking yard is probably your best bet. There are some I found on Ebay but they are asking a good percentage of the vehicle's value ($700-$800 US).

A google search found me Modine 3233871, which seems to be out of production but I found one here. https://isotigers.com/en/home/6120-intercooler-suitable-for-jeep-je512427-3233871.html

I have no affiliation or experience with that site, just found it searching for the Modine number. Happy hunting!

 

[Turboman280]

Is there enough of the bottom tube near the tanks to crimp it and roll it? That's what they used to do with bad tubes on radiators, although brass probably rolls better than aluminum.

 

[Jeff le Gascon]

Ok then, progress.
I cut out the bottom tube back to the end plates. Using a mini drill, cleaned it back as flush as possible,de-greased and rad-welded the small cover pieces in place:

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set up my pressure test kit

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And......i've got five holes in the tube above as well. I didn't see them during the first test as it was blowing so many bubbles from the bottom tube.
At least I know the fix worked, so I'm going to do the other one now. Crimping is not an option as the holes are so close to the end plates.

 

[Turboman280]

I wonder if solder would hold on those tubes?

 

[Jeff le Gascon]

Just wanted to tell everyone! she's fixed!!!!!!!
I am so f***ing pleased with myself.
Turbo spools up, no engine code, she goes like she should.
And all it cost was 15€
The seven radiator specialists I phoned should be ashamed of themselves!
I still have to put all the bits back I took off, and she still has to pas her mot/technical-control, but hey, looks like we can go to the mountains this winter.
I'll post the other photos of the job so far as soon as I have a few more minutes.