What is inside an intercooler?

[dpb]

I have found that one of my intercoolers is dripping very slightly, (leak of the week!) seems to be from the join between the main body and the top...but could also be the hose connections.
So I can see that I will need to split the components and presumably renew a gasket but what exactly is in there? I have looked on the parts diagram but can't work it out from that as it looks like a box in a box though I assume there is a matrix of some kind in there.
Just out of interest before I take it apart.

 

[PCUK]

Normally a cluster of small bore tubes that the cooling water passes through, the same as in a heat exchanger. In this case the hot compressed inlet air passes around the tubes and is cooled.

 

[Latestarter1]

You need to identify your motor, sealing arrangements can vary in detail. Simply a tube stack heat exchanger with cupro nickel core if it is a SWAC.

 

[oldgit]

I have found that one of my intercoolers is dripping very slightly, (leak of the week!) seems to be from the join between the main body and the top...but could also be the hose connections.
So I can see that I will need to split the components and presumably renew a gasket but what exactly is in there? I have looked on the parts diagram but can't work it out from that as it looks like a box in a box though I assume there is a matrix of some kind in there.
Just out of interest before I take it apart.

If it is a Vilvo AQD40A (square box) heat exchanger,can probably find some dismantling pix.
The internal heat exchanger on this version is very much like a normal car rad. folded back on itself.
Leaks can easily/cheaply be repaired with a "O" ring kit provided outer box is OK.
Howver the liberal use of silicone sealent can keep these things going if used with care.It must not get into internal cooling sytem.
Oops just realise you were talking about intercooler not heat exchanger .

 

[volvopaul]

I think your ad 41s ?

Under the lid is a square section rubber seal, it could be that or if you lift out the matrix the same seal is under there, I'd strip and examine the unit because it could lead to an engine failure should it leak badly into the cylinders.

 

[dpb]

Thanks for all that, yes its AD41s and looks like the top seal as there is white corrosion evident at some places.
Wondered about the possibility of water getting into the engine if something failed, so will get the spanners out sooner than later!

 

[STEVEDUNSTABLE]

this is the inside of my kad32 intercooler if your interested....this is march 2011 in the really cold snap -15ish !!!!!!... https://sites.google.com/site/thanksmums24/home/frost-damage this might be of interest also.. http://www.ybw.com/forums/showthread.php?t=265610&highlight=frost+damage

 

[dpb]

Steve, that is brilliant, thank you very much, I will have the same problem regarding room over the intercooler so your links will be very helpfull.
Thanks again!