2012-2019 Fiat 500 Intercooler: Leaks, P0299 Codes, and the Dual-Cooler System
A guide to diagnosing and replacing the passenger-side intercooler on 1.4L Turbo and Abarth models, including what to inspect on a used unit.
- This guide is for the passenger-side intercooler on 2012-2019 Fiat 500 Turbo and Abarth models, which use a unique dual-intercooler setup.
- The most common failure symptoms are power loss, a hissing sound under acceleration, and a P0299 underboost engine code.
- Failure is usually caused by cracked plastic end tanks or damaged hoses, not a problem with the aluminum core itself.
- When buying a used unit, you must pressure test it for leaks; a simple visual inspection is not enough.
Symptoms of a Failing Passenger-Side Intercooler
A failing intercooler is essentially a boost leak, meaning the pressurized air from the turbo is escaping before it gets to the engine. The symptoms are often subtle at first but become more noticeable as the leak worsens.
- Loss of Power and Acceleration: The car will feel sluggish, especially when you expect the turbo to kick in. It may struggle to build boost, and you'll notice a significant drop in performance.
- Hissing or Whistling Sounds: A distinct whooshing or hissing sound from the front passenger side of the car during acceleration is a classic sign of an intercooler leak. This is the sound of pressurized air escaping from a crack or bad connection.
- Check Engine Light with Code P0299: A significant boost leak will almost always trigger a Check Engine Light. The most common code associated with this issue is P0299 (Turbocharger/Supercharger Underboost). This code means the engine's computer is detecting less boost pressure than it expects.
- Reduced Fuel Economy: When the turbo system isn't working efficiently, the engine has to work harder, leading to increased fuel consumption.
- Visible Oil Residue: While a light oil film inside the charge pipes is normal from the crankcase ventilation (PCV) system, an external leak can cause this oil vapor to collect around the cracked area, attracting dirt and grime. A dirty, oily intercooler is a sign of a potential leak.
Known Issues, Recalls, and TSBs
As of mid-2024, there are no specific recalls or Technical Service Bulletins (TSBs) from Fiat or the NHTSA for intercooler failure on the 2012-2019 Fiat 500. However, the system has several known weak points based on owner experiences:
- Cracked Plastic End Tanks: The most common failure point for the OEM intercoolers. The plastic end tanks are crimped to the aluminum core. Over many cycles of heat and pressure, this plastic can become brittle and crack, causing a boost leak.
- Hose Failure: The rubber or silicone hoses connecting the intercooler to the rest of the turbo piping are a frequent source of leaks. Oil from the PCV system can soften the rubber over time, and constant pressure can cause them to split or pop off their connections.
- Road Debris Damage: Because the intercoolers are mounted low in front of the wheels, they are vulnerable to being hit by rocks and other road debris, which can puncture the core or damage the cooling fins.
Compatibility Warning: This passenger-side intercooler only fits 2-door Fiat 500 models equipped with the 1.4L Turbo engine, including the Turbo and Abarth trims. It will not fit non-turbo models. These vehicles use two intercoolers; this part is for the RIGHT (passenger) side only. The driver-side unit has a different part number.
Buying a Used Intercooler: A Step-by-Step Guide
A used OEM intercooler can be a great value, as it's a simple part with no moving components. However, you must inspect it carefully to ensure you're not buying someone else's problem.
1. Physical Inspection
- Check the End Tanks: Carefully examine the plastic end tanks for any hairline cracks, especially around the seams where they connect to the aluminum core and where the inlet/outlet pipes are molded.
- Inspect the Fins: A few bent fins are purely cosmetic and won't affect performance. However, look for large areas of crushed fins that could block airflow, or any signs of punctures or previous repairs (like epoxy or JB Weld).
- Examine the Ports: Ensure the inlet and outlet ports are perfectly round and free of cracks or damage that could prevent a hose from sealing properly.
- Look Inside for Oil: Shine a flashlight inside. A very light coating of oil is normal. If you see pooled oil or thick, sludgy buildup, it could be a sign that the donor car had a failing turbo, and that oil could be hiding a crack. Avoid units with excessive internal oil.
2. Pressure Testing (The Most Important Step)
A visual inspection can miss small cracks. The only way to be certain a used intercooler is good is to pressure test it.
Pro Tip: You can build a simple tester with parts from a hardware store. Get two rubber plumbing caps that fit snugly over the inlet and outlet. Drill a small hole in one cap and insert a Schrader valve (like a tire valve). Secure the caps with hose clamps, pressurize the intercooler to 15-20 PSI with a bike pump, and submerge it in a tub of water. If you see any bubbles, it's leaking and should be rejected.
Cost Comparison for a Fiat 500 Passenger-Side Intercooler
Repair costs can vary, but this table provides a general estimate for parts and labor.
| Item | Estimated Cost | Notes |
|---|---|---|
| New OEM (Mopar) | $160 - $225 | Part number 68073784AB. This is the most reliable option for a direct replacement. |
| New Aftermarket (OEM Style) | $100 - $180 | Fewer options exist in the OEM style, as most aftermarket parts are full front-mount conversion kits. Quality can vary. |
| Used OEM | $50 - $100 | A cost-effective option if thoroughly inspected and pressure tested. |
| Shop Labor | $200 - $400 | Labor typically involves 1.5-2.5 hours of work. |
Replacement Overview & Difficulty
- Difficulty Rating: 3 out of 5 (Moderate)
- Estimated Time: 1.5 - 2 hours
- DIY Feasible: Yes, for those comfortable with basic tools.
Replacing the passenger-side intercooler is a manageable DIY job. The front bumper does not need to be removed. The basic steps involve safely lifting and supporting the vehicle, removing the front passenger wheel and the plastic fender liner to gain access. From there, you will loosen the hose clamps on the inlet and outlet, disconnect the hoses, and unbolt the intercooler's mounting bracket. The horn is also attached to this bracket and will need to be moved aside. Installation is the reverse of removal.
Technical Specifications & Part Numbers
| Specification | Detail |
|---|---|
| Vehicle Fitment | 2012-2019 Fiat 500 (Turbo, Abarth) |
| Engine | 1.4L I4 16V MultiAir Turbo |
| Position | Right (Passenger Side) |
| OEM Part Numbers | 51819186, 68073784AA, 68073784AB |
Frequently Asked Questions (FAQ)
Do I need to replace both intercoolers at the same time?
No. The intercoolers are independent units. You only need to replace the one that is damaged or leaking. If one has failed due to age (cracked plastic), it's wise to inspect the other side, but replacement is not required.
Is a small amount of oil inside the intercooler normal?
Yes, a light film of oil is normal. The engine's Positive Crankcase Ventilation (PCV) system routes oil vapor back into the intake tract, and this vapor can condense inside the intercooler and piping. However, if you find a significant amount of pooled oil, it may indicate a more serious problem like failing turbocharger seals.
My intercooler is leaking. Should I upgrade to a front-mount intercooler (FMIC)?
Upgrading to a single, larger front-mount intercooler is a very popular modification for the Fiat 500 Abarth. An FMIC offers better cooling and can support higher power levels. However, it is more expensive and complex to install than a direct OEM replacement. For a stock or lightly modified car, a new or good used OEM intercooler is a perfectly adequate and cost-effective repair.
Could my P0299 underboost code be something other than the intercooler?
Yes. While a leak in the intercooler is a common cause, the P0299 code can also be triggered by a leak anywhere in the charge piping, a faulty wastegate solenoid, a sticking wastegate actuator, or a failing turbocharger. It's important to diagnose the entire boost system. Start by checking all hose connections between the turbo, intercoolers, and throttle body before replacing parts.
Technical Specifications
OEM Part Numbers: 51819186 68073784AA 68073784AB
Fits 1.4L MultiAir Turbo engine. Position: Right / Passenger Side. Part of a dual side-mount intercooler system.
The information in this article is provided for general reference and educational purposes only. Vehicle specifications, procedures, and part compatibility can vary by production date, trim level, and region. Always consult your vehicle's factory service manual and verify part numbers before purchasing or performing repairs. Safety-critical components such as airbags, seat belts, and braking systems should be installed by a qualified professional.
- Fiat 500:
- Symptoms of a Failing Passenger-Side Intercooler
- Known Issues, Recalls, and TSBs
- Buying a Used Intercooler: A Step-by-Step Guide
- 1. Physical Inspection
- 2. Pressure Testing (The Most Important Step)
- Cost Comparison for a Fiat 500 Passenger-Side Intercooler
- Replacement Overview & Difficulty
- Technical Specifications & Part Numbers
- Frequently Asked Questions (FAQ)
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