So I installed a new Intercooler over a year ago and recently had some issues with a tube from the waterpump to the thermostat housing cracking due to heat. The shop I took the car to did an airflow test and said the radiator is not getting enough air since the intercooler is so large.

Are there any solutions to this other than going back to stock intercooler??

 

I seriously doubt that the cracked pipe is due to the larger intercooler being installed a year ago. There have been thousands of oversize intercooler installed in series two MINIs over the years with no problems. You probably just had a tube with a manufacturing defect.

I wonder how they went about doing an airflow test? Is that even a thing they do on radiators in a shop?

 

shouldn't the fans keep the temp at level even if they have to run nonstop?

you might a bad thermostat? did you get a CEL?

 

The thermostat, housing, and both water pumps were replaced. There is a plastic hose that goes from the housing to the radiator and that is what cracked. They said it was due to higher radiator temps.

 

do you have a picture of that tube?

is it possible that it was damaged when the pump and TH were replaced?

I find it hard to believe that was the cause...my car overheated once and nothing happened to that pipe. I could be wrong, but for the mechanic, it is easy to just tell you "oh, your inter-cooler is big and made the car run hotter, that's why it cracked".

 

He said he had something hooked to it and said the temp was running a bit hotter than normal also...but I am not convinced since it took this long for something to happen. I think it cracked when the engine really over headed due to the waterpump(s) failing.

 

The water pipe from the thermostat to the water pump housing is very brittle, if you aren't careful you'll crack the end of the pipe that fits into the water pump housing.

There is only one section of plastic line for the coolant near the front of the car and it is from the thermostat to the expansion tank, and that is on the N18, we see those break due to fatigue of being pushed out of the way for oil changes, but other than that the only other problem with hoses would be due to rubbing on surfaces that cause the hose to fail.

Your intercooler had nothing to do with a failure like this, I wouldn't read too much into that theory, even the cheap intercoolers aren't causing overheating problems.

 

The mechanic is saying not enough air is getting to the radiator. :/

 

When the pass side water pump was replaced, the shop had the option to also replace the plastic coolant pipe that is on the REAR of the engine . It runs horizontal and connects to thermostat housing on drivers side of block above transmission. These are tender and can easily get %^^#£ up when putting pump in. The car may be running hot, but that’s a “coolant system “ issue. The inter cooler install has never caused overheating that I have seen. Best practice is to flush coolant, get all the air out of the system and use the bleed screw. Than pressure test the system overnight at the coolant bottle fitting and see where the leaks are, if any.
Its likely he never purged all the air out before and the car began running warm. Might consider finding a new tech that will be more honest with you and partnering to find solutions. The best techs mess up, but work with their customers for long term loyal business. I never look for “ perfect techs”- just ones with integrity.
Keep us posted and fingers crossed that all is ok!