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Little Megger
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46 Posts
Discussion Starter · #1 ·
Hi Chaps, I was encouraged by randall's topic to clean the EGR valve on my 02 reg Mondeo TDCI 130. During dismantling the EGR valve, I found a 7cm long crack on the corner of intercooler pipe connected to the EGR. A bit of gunk out of the crack. Now I have a bunch of questions needing your help. :tonofbricks:

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!!!
 

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Big Megger
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188 Posts
Mine went , 4 inch gash, common problems. very easy fix yourself (£20), yes it does cause even more smoke and terrible consumption.
 

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Little Megger
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46 Posts
Discussion Starter · #3 ·
Thanks mjw69. Is it easy to take the front bumper off? Is the £20 you mentioned for the price of the pipe itself from Ford? BTW, can I temporarily bind the pipe using some multi-purpose tape before I get a new pipe? :driving:
 

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Little Megger
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46 Posts
Discussion Starter · #5 ·
Thanks graemewelch. I will try to fix it by myself. Regarding my first question -- "Is the gunk out of the crack is from the intercooler or exhaust gas?", what is your opinion? Or how can I detect the source of the oily deposit at this pipe crack? Another thing is that I do see oily deposit covered the air cleaner outlet pipe connecting the turbo charger. Is that indicate some problem? or it is normal for a car with 133821 mileage?

Cheers.
 

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Big Megger
Joined
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254 Posts
Hi, same problem with mine. go the pipe today.
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?
 

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Little Megger
Joined
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46 Posts
Discussion Starter · #7 ·
Thanks Tred. I may think too much about this oily gunk. I will try to get this pipe from local motor factor today. See how cheap the price is compared with Ford dealer. Cheers.
 

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Big Megger
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254 Posts
I replaced it there at lunch time. the inside of the pipe did have a black oily fillament on it. actually it was like oil. Anyone here know if thats a symptom of a possible serious problem. Should that pipe be bone dry?.
 

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Little Megger
Joined
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46 Posts
Discussion Starter · #9 ·
I went to a local garage this afternoon. They give me a quotation £31 for the pipe from other supplier. But they offered me £10 labour for fitting. I think £10 labour is cheap without get my hands dirty. So I decided to have it done in this garage tomorrow if the parts arrives. On the way back, I popped in the Ford dealer, the quotation is £30.53 which is 50p cheaper than what I get from the local garage. So some parts are not necessarily expensive from the Ford dealer.

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! :)
 

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Megger
Joined
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155 Posts
10 quid to have it fitted is pretty good.

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.
 

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Big Megger
Joined
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254 Posts
Interesting, I didnt know that. I know that the turbo uses some engine oil sometimes to lubricate the bearing internally, in the turbo if a seal was leaking there, it could cause oil to come back that pipe id say. that was my concern. leaking oil from turbo could spell disaster. anyone else here ever see oily gunk in this pipe when replacing.
 

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Little Megger
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46 Posts
Discussion Starter · #12 ·
Thanks Getafix. The supplier of my local garage is useless. They didn't send the correct pipe to the garage. So this afternoon I bought this pipe from Ford dealer and got the refund from the local garage. So I will try to do it by myself. Finger is crossed. :kaffeetrinker_2: BTW, how tight I need to screw the nut to fasten the pipe to EGR. If I tight it too much, will it damage the rubber of the pipe?

Cheers,
 

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Diesel Head
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1,929 Posts
I think youll find all turbo diesels have oily residue inside the intercooler pipes and the I.C. the exhaust recirculation valve adds to this oil residue as does the engine breathing system :kaffeetrinker_2:
 

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Megger
Joined
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155 Posts
The pipe is held on by a couple of jubilee clips if memory serves me right. They only have to be "nipped up", the pipe is only at a few psi.
 

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Little Megger
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46 Posts
Discussion Starter · #15 ·
Thanks Gatafix. I am not a native speaker. Sorry for my poor English. I guess you meaning is I don't need to tighten the jubilee clips too much. Am I right? I found I have a habit of tightening nuts till it cannot be tightening any more. Sometimes I did damage nuts. :(
 

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Registered
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319 Posts
yes dont do them too tight just a gentle hand tight will be fine as long as you can pull the pipe off with a firm pull you will be fine.
 

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Little Megger
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46 Posts
Discussion Starter · #17 ·
yes dont do them too tight just a gentle hand tight will be fine as long as you can pull the pipe off with a firm pull you will be fine.
Sorry randall, do you mean "as long as you CANNOT pull the pipe off with a firm pull"? :)
 

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Big Megger
Joined
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254 Posts
Hi Adsi. I did mine on Monday. I used a flat head screw driver to open the top jubilee clip, and then there was enough play to remove it from where its connect to EGR. The i went under the car, and there wasnt really room to work with a screw driver so i used a small wrench to slowly open the bottom jubilee clip. once opened, i was able to push that off nice and handy, not to damage anyting else :) then i took out the damaged pipe. i place it beside the new one, so that i could confirm they were correct, then i went from the top and pushed down the pipe into position and connected it to EGR. i didnt tie jubilee at that point, as it hought it might need some play to get it in below and i was right. Then after i eased it over the pipe in bottom, tighted the jubilee clip and then tigghted the one above. ull notice when u unscrew those clips, there not tighht anyway, so u dont need them to be machine tight.
 
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