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Crack on intercooler pipe, easy fix?
Posted 10 February 2008 - 03:25 AM
1. Is the gunk out of the crack is from the intercooler or exhaust gas?
2. I wonder if the intercooler pipe crack is the reason of the exhaust smoke increase and bad fuel consumption recently?
3. How easy is it to change this pipe? I looked at the Haynes Manual. It looks I need to take the front bumper off to access the other side of the pipe connecting to the intercooler. Any tricky bit to take the front bumper off? I didn't have much mechanical exprience before. This is my first car. :doh:
4. How much is the labour for change this pipe in a normal garage (not Ford dealer)?
Thanks for any answer!!!
Posted 10 February 2008 - 03:35 AM
Posted 10 February 2008 - 01:59 PM
Posted 10 February 2008 - 04:54 PM
Posted 10 February 2008 - 11:54 PM
Posted 11 February 2008 - 11:25 AM
There is some oily gunk as well coming out of mine, but if you think about it, if there is an issue wiht EGR getting blocked at times wiht carbony deposits, maybe this is what this stuff is. Id love to know as well if i have a serious problem. Randall mentioned possibly issue with turbo seals, but i think i overstated the oily gunk. Amazing same pipe cracking for so many isnt it. Id say if you took out the pipe,cleaned it down good and then got good quality tape, i bet it would get u by for a year?
Posted 11 February 2008 - 12:13 PM
Posted 11 February 2008 - 03:19 PM
Posted 11 February 2008 - 06:19 PM
Regarding the oily gunk in the pipe, my colleague told me it is normal because the crank case ventilation pipe sends some diesel + air mixture to the air intake pipe to the turbo charger. Looking at the pipe after air filter, it has a small branch pipe to the engine which is the ventilation pipe I think. So the the intake air will have a little amount of diesel inside anyway. That's why the pipe has some oily gunk. I am just a novice, so any comment is welcome!
Posted 11 February 2008 - 07:59 PM
It can be done by removing the bottom engine cover but it's a pain lying on your back.
The area where the pipe splits is very close to the block and gets hot. Trying to seal it with electricians tape will only last a day before the sticky melts and the tape slide down the tube. Wrapping it with duct tape will last a couple of weeks tops.
While your on with the hood up - clean the EGR valve with carb cleaner (you'll chugg a bit on start up and belch a bit of smoke but it should clear after 15 - 20 seconds). Also, get some electrical cleaner from Maplins and clean the air flow meter wires CAREFULLY - two screws just after your air filter. They should be thin and shiny NOT furry and black.