Engine: D5: - Intercooler Hoses - How Hard?

Mr-V70 · Dec 29th, 2007, 11:04

Having posted recently regarding the smoking issue in my D5 it looks like the intercooler is to blame, however yesterday I got an able assistant to rev the car whilst I felt the hoses.

How hard are the hoses supposed to go when the car is revved? Both hoses got harder, but even at 4000 revs I was able to squeeze them, although you could feel that they definitly did get harder. Interstingly both hoses felt to be about the same, which if the intercooler was split I would expect one to be less hard than the other?

The inlet hose to the intercooler is jubilee clipped onto a plastic looking hose that passes under the engine, do these ever split?

Cheers

Happy new year everyone!

Sam

Clan · Dec 29th, 2007, 14:04

therewont be much boost pressure just revving the engine as there is no load on it . As long as you feel the pressure rise a bit it's ok .. No the plastic pipe under the engine doesnt split on the old D5 , only the 2005 onwards models after Ford bodged around with the pipe to cut costs !

Mr-V70 · Dec 29th, 2007, 15:50

Thanks very much. I think the hoses are OK then.

I have looked underneath and peering through the undertray I can see a large build up of gritty oilly black stuff around the base of the radiator on the passenger side corner. It is also all over the auto trans hoses and the large braided hose (i dont know what it is LOL).

I am going to take the front part of the undertray off tomorrow and have a better look.

I am 90% sure its the intercooler now, only I dont want to buy one unless im sure because they are so expensive!!

Cheers for your help, I will post photos of the mess tomorrow!

Sam

Clan · Dec 29th, 2007, 15:59

Thats oily crankcase fumes leaking out of the intercooler together with the clean air , its pretty conclusive .

111 · Dec 31st, 2007, 22:49

Don't take this as gospel but I was told that the intercooler has a hole in it when it is new to allow the oil to drain. But I would say if this was true then it is a very poor way of dealing with a problem.

Clan · Dec 31st, 2007, 22:55

Yes the 800 series has this small 2 mm hole and it is aimed into a labrynth in the air guide tray to evaporate off in the air stream its a good idea actualy ..
But the later cars don't have this feature

111 · Jan 1st, 2008, 11:50

Quote:

Originally Posted by Clan

Yes the 800 series has this small 2 mm hole and it is aimed into a labrynth in the air guide tray to evaporate off in the air stream its a good idea actualy ..
But the later cars don't have this feature

So this wouldn't apply to a 2003 S60 D5 then ????

Clan · Jan 1st, 2008, 11:59

NO the cars after 2000 don't have the hole .

111 · Jan 1st, 2008, 12:00

Thanks for the info, mine must be leaking then, Bummer. It has been the same from 61K now on 67 but with no smoke.

Mr-V70 · Jan 1st, 2008, 21:29

I've booked the car into Volvo tomorrow to have the intercooler replaced - for £450 includin vat.

Bargain......... Not.

I have no choice though the smoke has got a lot worse over the past few weeks and i might get mistaken for one of the red arrows

I just hope it solves the problem. I will ask Volvo to leave the old intercooler in the boot and will post a photo.

Cheers

S

Dec 29th, 2007, 11:04	#1
Mr-V70 Senior Member Last Online: Feb 6th, 2019 22:28 Join Date: Jul 2007 Location: Nr. Ashford, Kent	Intercooler Hoses - How Hard? Having posted recently regarding the smoking issue in my D5 it looks like the intercooler is to blame, however yesterday I got an able assistant to rev the car whilst I felt the hoses. How hard are the hoses supposed to go when the car is revved? Both hoses got harder, but even at 4000 revs I was able to squeeze them, although you could feel that they definitly did get harder. Interstingly both hoses felt to be about the same, which if the intercooler was split I would expect one to be less hard than the other? The inlet hose to the intercooler is jubilee clipped onto a plastic looking hose that passes under the engine, do these ever split? Cheers Happy new year everyone! Sam

Dec 29th, 2007, 14:04	#2
Clan Experienced Member Last Online: Yesterday 22:27 Join Date: Jun 2007 Location: L/H side	therewont be much boost pressure just revving the engine as there is no load on it . As long as you feel the pressure rise a bit it's ok .. No the plastic pipe under the engine doesnt split on the old D5 , only the 2005 onwards models after Ford bodged around with the pipe to cut costs ! __________________ My comments are only based on my opinions and vast experience .

Dec 29th, 2007, 15:59	#4
Clan Experienced Member Last Online: Yesterday 22:27 Join Date: Jun 2007 Location: L/H side	Thats oily crankcase fumes leaking out of the intercooler together with the clean air , its pretty conclusive . __________________ My comments are only based on my opinions and vast experience .

Dec 31st, 2007, 22:55	#6
Clan Experienced Member Last Online: Yesterday 22:27 Join Date: Jun 2007 Location: L/H side	Yes the 800 series has this small 2 mm hole and it is aimed into a labrynth in the air guide tray to evaporate off in the air stream its a good idea actualy .. But the later cars don't have this feature __________________ My comments are only based on my opinions and vast experience .

Jan 1st, 2008, 11:59	#8
Clan Experienced Member Last Online: Yesterday 22:27 Join Date: Jun 2007 Location: L/H side	NO the cars after 2000 don't have the hole . __________________ My comments are only based on my opinions and vast experience .

Dec 29th, 2007, 15:50	#3
Mr-V70 Senior Member Last Online: Feb 6th, 2019 22:28 Join Date: Jul 2007 Location: Nr. Ashford, Kent	Thanks very much. I think the hoses are OK then. I have looked underneath and peering through the undertray I can see a large build up of gritty oilly black stuff around the base of the radiator on the passenger side corner. It is also all over the auto trans hoses and the large braided hose (i dont know what it is LOL). I am going to take the front part of the undertray off tomorrow and have a better look. I am 90% sure its the intercooler now, only I dont want to buy one unless im sure because they are so expensive!! Cheers for your help, I will post photos of the mess tomorrow! Sam

Dec 31st, 2007, 22:49	#5
111 Darkest Stockton-on-Tees Last Online: Jun 4th, 2024 18:03 Join Date: May 2007 Location: Stockton-on-Tees	Don't take this as gospel but I was told that the intercooler has a hole in it when it is new to allow the oil to drain. But I would say if this was true then it is a very poor way of dealing with a problem.

Jan 1st, 2008, 12:00	#9
111 Darkest Stockton-on-Tees Last Online: Jun 4th, 2024 18:03 Join Date: May 2007 Location: Stockton-on-Tees	Thanks for the info, mine must be leaking then, Bummer. It has been the same from 61K now on 67 but with no smoke.

Jan 1st, 2008, 21:29	#10
Mr-V70 Senior Member Last Online: Feb 6th, 2019 22:28 Join Date: Jul 2007 Location: Nr. Ashford, Kent	I've booked the car into Volvo tomorrow to have the intercooler replaced - for £450 includin vat. Bargain......... Not. I have no choice though the smoke has got a lot worse over the past few weeks and i might get mistaken for one of the red arrows I just hope it solves the problem. I will ask Volvo to leave the old intercooler in the boot and will post a photo. Cheers S

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