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Just Throw some Flakes in your cooling system ,does no harm and stops leak in 2min flat.
Look in the Vendor section for Diesel Smart, I cant praise them enough Cheapest change over Intercoolers out...

Sounds good I used to live in Bagot Rd ,
Anyway what condition is your intercooler in? oily on the outside?
if it is chances are its leaking, I ended up fitting a Tigged Intercooler
and found my...

Can we get an update on how you are going.??

Look up manuel boost controler in the search button by the same bloke above^^^

http://www.chaz.yellowfoot.org/zd30_engine_problems.htm