Was just talking to Phil (from Wollongong). He is in the process of changing his timing belt. He noticed a bit of oil on the top of his intercooler during all the disassembly. Had the intercooler pressure tested in a water tank and it was leaking. A tube weld cracked near the top on the side where the CAC In hose joins the intercooler plastic tank. Apparently this type of fault is common in Nissan's. Maybe it has something to do with the engine movement of the CAC IN hose stressing the intercooler assembly - just my speculation. I have never heard of it in KJ CRDs and there is no evidence of it that I can find but it might be worth a look if your doing that job. The tube can't be welded as its too close to the plastic tank and it can't be disassembled because it can't be resealed. So he went off to Jeep to price a new intercooler. Are you sitting down? It was $2720! No aftermarket replacements due to all the clips and such that are part of the molding. You could (maybe) source a universal type but it would have to be mounted right up front somehow.

Anyway he went to a truck intercooler specialist who he was referred to and this guy says he can fix it with a metal putty (sort of an epoxy I guess) and that it will seal it and not open up again. Obviously Phil is rapted - its only going to cost him $100 to fix this way.

Got to get the name of this miracle putty!

After Phil's dramas I ran across this -same problem but the new intercooler in the US is $700!

viewtopic.php?f=5&t=50589&hilit=+intercooler+leak


Update on the putty - there are a few on the local market. Locktite makes one and the real impressive one seems to come from Devcon

http://www.devcon.com/prodfiles/pdfs/fam_tds_107.pdf

http://www.moore-international.com/loct ... l_set.html