Another Blown Intercooler

[Dancake]

I understand your thinking cheshired5. Any blockage can cause pressure issues. It wasn't that long ago that I cleaned out the EGR plenum pipe, and there wasn't that much carbon in it. The oily carbon build up could quite easily make its way down to the passenger side of the intercooler, but I am not sure than this is the cause. Most bowed D5 intercoolers seem to be pretty symmetrical. The bow in the centre seems to pull down on either side, separating the sides of the intercooler. Might do some intrusive investigation and disect the old intercooler when it comes out.

[Brendan W]

I suspected condensation in the i/c was either freezing or hydro-locking water hammering. Recently I changed out a rad on an E38 728 beemer. The core had failed in exactly the same way as the intercoolers. Lower elements bowed, all that was missing was the oil. Somehow I think they haven't got this plastic side tank thing quite right yet.

[cheshired5]

Originally Posted by Dancake

I understand your thinking cheshired5. Any blockage can cause pressure issues. It wasn't that long ago that I cleaned out the EGR plenum pipe, and there wasn't that much carbon in it. The oily carbon build up could quite easily make its way down to the passenger side of the intercooler, but I am not sure than this is the cause. Most bowed D5 intercoolers seem to be pretty symmetrical. The bow in the centre seems to pull down on either side, separating the sides of the intercooler. Might do some intrusive investigation and disect the old intercooler when it comes out.

Thanks for that. Admittedly, I haven't seen loads of blown I/Cs.
It is ultimately an air radiator though so oil shouldn't be there but obviously is so to me that means that if it's not making its way down from the mixer plenum, it can still come from the turbo feed which has an element of exhaust gasses along with fresh air.
The fresh air is filtered so unless oil seals are going in the turbo, there aren't other ways for oil to enter the intercooler.
That's my logic anyway.

[Rossi-fan]

I was always told that these engines suck up oil deposit's from day 1 of their lives. It's just how they work apparently.

[cheshired5]

Originally Posted by Rossi-fan

I was always told that these engines suck up oil deposit's from day 1 of their lives. It's just how they work apparently.

True, they ain't clean no matter what but something happens more on some than others.
Mines still on the original intercooler when others have needed them at half my miles.
I can't take too much (or any) credit though as it was at 150k when I bought it.

[Rossi-fan]

Originally Posted by cheshired5

True, they ain't clean no matter what but something happens more on some than others.
Mines still on the original intercooler when others have needed them at half my miles.
I can't take too much (or any) credit though as it was at 150k when I bought it.

Mine went at just over 100k, strange eh. When they really get bad, it does just look like an oil leak, only right at the very front of the car.

[Rossi-fan]

Are you sure it hasn't had a replacement before you bought it ches? Its done well if it hasn't. I'm wondering if how long they last depends on how the car has been driven during its life. Maybe a car that's been driven hard by someone, things like the I/C (amongst other things) will have a shorter life span. I'm just guessing here before someone rips me to bits.

[Dancake]

The intercoolers seem to last longer on automatics than manuals before they fail. There will always be oil getting passed to the intercooler from the turbo. It's when it starts to pool at the base of the intercooler that you should start to worry. Even new cars do it.

I think the air filter box and the intercooler aren't big enough in the Euro 3 D5's. A bigger filter and intercooler would help tenfold. You can even see it on the air filter boxes where they swell at the edges.

[cheshired5]

Originally Posted by Rossi-fan

Are you sure it hasn't had a replacement before you bought it ches? Its done well if it hasn't.

Of course I can't be certain but going from the impressive folder of receipts which shows (what I think is) everything that's been done, it seems not.
The previous owner may have left it out but they seemed very thorough with the maintenance so I doubt it.
I've got bills with everything from clutch to belts to bulbs as well as routine servicing then I bought it and now there's nothing, except videos.

[Rossi-fan]

My car runs just fine at the minute, its the paint work that lets it down. I've got lacquer peeling off here and there, and it just doesn't look nice any more. 😦