Passat (B5) :: Seems Like The Intercooler Is Leaking At The Bottom


Jul 30, 2008

I just changed the oil in the 04 GLS. It looks like the intercooler is leaking at the bottom hose. It does leave marks on the garage floor. Also I may have rear main seal leak too.

The car has 45K on it

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Truck is completely stock (93K miles) so was wondering what root cause of this might be? Just a failure of the component from age? Boost too high, suggesting an issue with the turbo?

CAC boot that connected closest to the damage may have been leaking, but not sure if that could cause that much oil spray?

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I don't believe I have seen this condition in the winter months 40 - 50 F degrees when using just the heater. I'm hoping this isnt systematic of another problem, that was simply explained away by dealer. It sounds logical but then, again, I have never seen it when using the heater. I do leave heater at full blast when I start the car remotely to warm up cabin temp on those cold chilly mornings.

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Now it seems to be leaking from the very same area, what I mean is the area around the hose is dry but just up the seam a bit it barely leaks, and mainly after the truck cools off at night. These radiators seem extremely low quality, is there a substitute higher quality.

Also of note mine is the 1" core, I was told there are others but they will not fit, I must agree it seems nothing else would fit due to space constraints. These radiators just kinda sit in a cradle and aren't really under any stress that I can tell so it doesn't seem as though that would be the cause.

Also of note the shop where I bought the new one took it out of the sealed box and tank pressure tested it as they do for all new sales, no leaks, I have not pulled it back out yet cause I would like to get some thing less flimsy if it exists.

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2004 f250SD 5.4 83000miles

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