Water to Air Intercooler damages motor.

[macca]

My first guess to the root cause of this issue would be stray current.

@macca. I just have a normal .9 bar radiator cap on mine

Just north of 13psi, about what my turbo is set at, some run much higher boost but not near 60psi John talks about.
As you indicate it has to be something else.

[nissannewby]

If it was an internal split from too much pressure wouldn't it more likely be the air pressure causing it rather than the water pressure? Just like when a regular air to air intercooler splits

>>>tappin from tassie

It would have to be a lot of pressure to split it. These things wil run at 30+ psi without a problem. Poor mounting or as ben-e has stated poor system maintenance resulting in electrolysis.