Intercooler blown? 12 plate Navara V9X
Hi. I'm new to posting here, although have been a "reader" for a while - and benefited from lots of good advice so far, so thanks!
My truck is in limp mode most of the time, and I've just found my intercooler looks like it might be blown - photo attached.
I've searched the forums and picked up as much as I can, which has got me to this point.
The truck is on a 12 plate with about 70k miles, FSH with Nissan for the first 5 years and local garage for the last 2.
The local garage did an EGR blank & delete and power boost in March 2018. (Second EGR fail in 6 years, first fixed by Nissan under warranty at 2 years old - so I didn't want to fork out for a third valve). That is the only mod.
I wasn't fussed about the power boost, and may now regret saying yes - they said it was included in the price and they'd done loads before ...
Limp mode started as intermittent a few weeks ago - engine re-start cleared it for sometimes a week, sometimes a couple of days. No check engine light at all. The Cruise Set light flashes when in limp - I can't find any reference to that in the manuals.
Last service was end March this year (new fuel & air filters fitted). Limp mode was intermittent at the last service and they couldn't identify the issue.
Limp is now pretty much constant.
It's got a P012b code logged (thanks to this forum for the Torque OBD recommendation) and a look around checking the charge air path shows two vanes on the IC bowed and lots of oily gunk. I think I can feel air escaping although it's hard to tell with the engine fan also going, plus the air feels cold and I'd expect it to be warm? All pipes appear to be sound.
Please can anyone help with questions?
Has anyone seen an IC with this type of damage?
Could it be caused by the turbo boost set too high with the March 18 remap? (Car was fine for 10 months after, noticeably quicker)
It seems likely to me that a leaking IC could cause the boost pressure drop and give the P012b code - does that sound likely?
Any tips for testing for a leak before I remove the IC?
Does anyone know where I can either get the IC reconditioned or buy a replacement - and likely costs? A web search so far is looking like £400+
Does the bumper have to come off to remove/replace the IC? The workshop manual says it does, but has anyone done one just removing the grille?
Any tips or things to watch for removing the bumper and grille?
I've got the workshop manuals (Spain and Thai) on pdf - I'm happy to share them via Dropbox if anyone on here needs them.
I'm sure there are other questions I should be asking, so any and all help will be appreciated.
Thanks in anticipation, Mike