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Old 08-11-2013, 02:49 PM   #1
nevetsg
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Default Oil leaking from intercooler. TDCI

Hi

Wife call me this morning saying that we were leaking oil near the front of the car. I got her to check the level and it was OK so she said she would drop by a mechanic. He discovered that it was leaking from one of the seals for the intercooler and refereed us to Diesel experts near by.

Now, my googleing just now suggests that some is OK/normal and maybe I just have to clean it out and see if it builds back up again. However, Lots of oil could be the turbo seals on the way out. I was thinking option 1 and keep an eye on it.
The car has done about 122,000Km.

Thoughts, ideas, expert advice?

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Old 08-11-2013, 03:26 PM   #2
mac_man_luke
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Default Re: Oil leaking from intercooler. TDCI

you will get a fair amount of oil from the PCV

You can install a catch can (e.g. provent 200) which will prevent build up.

Also a sign the intercooler is slightly leaking, could replace it with a higher quality aftermarket model
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Old 08-11-2013, 03:37 PM   #3
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Default Re: Oil leaking from intercooler. TDCI

So I called Diesel experts and the first thing he asked was if I have had any work done on the front end. Well, yes we had a smash that was repaired by the worst repairers ever 4 months ago.
Now I am guessing that the Oil is the normal build up and the intercooler got cracked/seal broken in the smash. It is going back in to get fixed (forth time back) again next week they can determine if it is related then.
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Old 11-11-2013, 03:10 PM   #4
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Default Re: Oil leaking from intercooler. TDCI

I got under the car yesterday and undid the 17 screws and 4 plastic clips to remove the front under guard. I could see that the oil was definitely coming from where the intercooler out connects to a hose up the engine. There was a fair bit of gunk on the top of the front under guard and all around. The ring clamp was pretty tight so i started and revved the engine to 3K for a bit, I could see a small drop of oil start to appear.
I tried for ages to get the pipe separated at that section but failed, tried up at the manifold as well... After loosing the clamp what magic does it take to get those things apart?
cleaned the area and put all back together; will think about it again after smash repair.
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