98 S70GLT Was MAF Issues, Now Intercooler Damage

[ncaapicks]

I addressed my current issues in this thread:
https://www.matthewsvolvosite.com/forums ... =1&t=65230
I was investigating my intercooler lines under load and found this after hearing hissing well below the front end of the car:


!!HOLY GEEBUZ!! I remember hitting some tread being spun off a tractor trailer ahead of me over two years ago, but did not find anything upon inspection and no codes other than a persistent P0442. Perhaps it popped loose hitting a curb stop?

This looks like gross leak, correct? Am I looking at a new intercooler or can the plastic bottom be replaced? Can I hold off buying a new MAF until I get this resolved?

I need to touch base with MadeInJapan. He mentioned in an old thread about some guy who was able to fabricate an aluminum replacement.

A couple of weeks ago, my car stalled and I literally limped home. Car would start without trouble,but could not get a decent idle before stalling again. I pulled the following codes:
P0108 - MAP Pressure Circuit High Input
P0171 - System Too Lean (Bank 1)
P0243 - Turbocharger Wastegate Solenoid A Malfunction
P0442 - Evaporative Emission Control System Leak Detected (small leak)
P0455 - Evaporative Emission Control System Leak Detected (no purge flow or large leak)
P0505 - IAC (Idle Air Control) System Malfunction
*No code presented for my MAF sensor.

I found that by unplugging the MAF, the car would run with little variation in idle. I'm in the middle of replacing all my vacuum lines and have those that originate and/or terminate down near the turbo and the bottom of the air intake tube left to do.

I'm currently getting a P0102 (unplugged) and a pending P0171. Also have received P0243 intermittently.

[Ozark Lee]

The intercooler, unfortunately, has nothing to do with the evap codes. The P0171 and possibly the P0243 are possible. The car has to run like crap so I would deal with the intercooler first and then figure out what codes come back. With a list that long it is divide and conquer.

...Lee

[tryingbe]

Replace that intercooler, don't attempt to repair it.

It's cheap, and all over the place.

[ncaapicks]

Update:
Found an old intercooler (paid a little more than I had hoped) and all is good. Getting mine out wasn't bad, but installing the "new" old one was much less pleasant. I think the entire effort took me about 6 hours.

My P0171 is gone, MAF does not need to be replaced, and it's nice to get some boost back in my turbo. During my test drive, I heard a pop and things went to hell. I pulled off the road and found the upper intercooler hose had popped off. I must have overlooked that clamp.

Next up, turbo vacuum lines and my EVAP lines/hoses.

[Ozark Lee]

It does get your attention when the hose pops off, it happened to me as I tried to accelerate onto a highway with a short merge lane. It was an Oh Sh*t moment.

...Lee

[ncaapicks]

Too funny. That is exactly what i said...along w/ you f'n idiot.