With all the recent talk of leaking intercooler pipes on the JTD I thought i'd check mine over as i've had the odd whistle/whoosh.

So i whip the undertray off and this is what i'm confronted with





What's you initial opinions?


under the engine i found this,






The intercooler pipe, oil catch tank pipe and the other pipe that links MAF to Turbo and top of engine (similar to item 10 on the pic below) were all overed in a really think oil. It has obviously been there ages as most of it was very dry and crumbly.




I managed to clean everything off and can't find any splits in any of the pipes although the pipe mentined above is a bit floppy in parts.
I think this pipe was loose at the turbo end, it had a jubilee type clip on but you could move the whole pipe with your hand about 8 mm which can't be right can it?
I stripped out the lot, cleaned and replaced with all new jubilee clips, i'll have to see how it goes.

I also stripped out the entire lower intercooler pipe, (two rubbers hoses with metal pipe in the middle) the outer rubber pipe that attaches to the intercooler in the wheel arch area had two quote deep rub marks that showed a sort of fabric/textured layer (abit like the cord in a car tyre). I've gaffer taped this until i can get a new pipe.
The upper intecooler pipe that leads back into the top of the engine was fine.

Sorry for the long description, comments please

I gave mine a nice clean a while back (hope you cleaned the undertray too) and it's a real mucky job :yuck:

You'll most likely find if you check in a month or so it will still be nice and clean (was when I checked mine)

I presume you've made sure your MAF is not getting oil contaminated ?

The maf was fine from what i could tell, i wanted to take the MAF out but the lower bolt just turned round and round without coming out
All the oil/dirt was below the turbo, nothing above.
I'm not sure whether my IC pipe was leaking or not, performance is good and MPG 48-53 depending on driving style.
the only thing i'm not happy with is the amount of smoke when booting it and an annoying chattering type noise when accelerating under load upto 2500ish RPM.
I thought that may be a spilt pipe but was still there after the work i did yesterday.
Maybe my turbos on its way out?

cleaned your EGR valve yet? If you have good acceleration, you have a good turbo.
Chattering noise could be caused by an injector not working correctly.

Also could be an injector seal which is cheap and easy to replace.

john55 said:

cleaned your EGR valve yet? If you have good acceleration, you have a good turbo.
Chattering noise could be caused by an injector not working correctly.

Also could be an injector seal which is cheap and easy to replace.

Click to expand...

No I haven't attempted the EGR Valve yet, i'm building up the nerve to start taking those sort of things apart, i am just wary as it only takes a wrong fit/seal and you get problems.

Acceleration is great as it's remapped :devil: one thing i found today to and from work is that it seems smoother on and off the power and a bit punchier, not quicker if that sounds right. Also not as much smoke.
I think the Maf pipe as i call it was definately not fited right where it attached the the turbo; as I described before, being able move it so much must have been letting air out, it doesn't move at all now.

Didn't really listen for the chattering today, it only occurs when i can't be bothered to change down and the load on the engine is more than normal, ie. doing 40mph in 5th steady and then floor it up to 70mph for the first bit the chatter starts but then as the revs rise into the comfortable zone it disapears. weird, i'll chuck some injector cleaner through it next time i fill up and see how that goes.
I also want to use the Forte engine flush I bought ages ago but got to wait a while before due an oil change again. Upto 106,000 now.