I went to Charleston SC this morning and while trying to accelerate on the on ramp to I26 the motor sputtered and blew white smoke again. This also happened a month ago and I pulled the intercooler off and drained about a cup of water out of it. After it did it again today I said that when I get back home I was going to fix this problem or at least make it easier to drain the water. I took the intercooler off and there was more than a cup of water in it. I drained it out and proceeded to install a drain ****. The bottom would be the best place but I would have to weld an aluminum piece to it to add depth for the threads. On the side of the intercooler there is a spot that is thick and low enough for the water to drain out. I drilled out a 7/16 hole, tapped it with a 1/4" pipe tap, placed some thread tape, and tighten the drain **** into the intercooler. So far it works great, just start the engine, open the drain **** 1/2 to 1 turn, and the water pours out as if it was on an air compressor tank.
I can't post the pics but here is a link to my albums.
I had that done the first of this year but when the humidity is high the moisture still collects/condenses in the CAC/intercooler. Now I can drain it out without having to take the unit off. I live in SC and the humidity has been high here for about two months straight.
This idea had been shot down previously, with concerns of weakening the intercooler, but it looks like you've managed to do it in a way that addresses this. Great post! Wish I'd just done this instead of going through the TSB hassle.
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