Cracked water-cooled intercooler on the 1.6 and 2.0 TDI EA288: coolant loss with no external leak

Engine / equipment

1.6 and 2.0 TDI EA288 with the intercooler inside the intake manifold, liquid-cooled

Period mentioned

All EA288 years

Symptoms

The coolant level drops and needs frequent topping up, but there is no visible stain or drip outside; there may be some white smoke. A clue: a greasy oil-and-water paste on the block next to cylinder 4, near the bulkhead.

Possible cause described

On these engines the intercooler sits inside the intake manifold and is cooled by the engine's own coolant. According to Schaeffler (REPXPERT), repeated heating and cooling can open fine cracks in its inner mesh: the coolant does not leak outside but passes in small amounts into the cylinders and burns, which is why the fault goes unnoticed.

Check for the garage

The garage can check it before removing the manifold: take out the intake air temperature sensor, insert an endoscope camera through its hole, pressurise the cooling circuit and look at the intercooler's inner fins. Have them also rule out the EGR cooler and the head gasket, which give similar symptoms.

Cost cited in the source

No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.

Sources from the original database