Tube size

jscpch · 7th August 2015, 14:35

2003 cdti. Can anyone advise please. The large diameter black tube from the turbo to the lower part of the oil intercooler - are there different sizes?
I live in Spain and had some problems with small regular oil leaks from the pipe which is fitted with two O-rings. Took it to a good English owned garage and they told me that if they fit the O-rings as appears to be correctly that one is still not in the intercooler connection.
They did the repair a couple of months ago when they removed the radiator to get good access but it started to leak again after a couple of weeks.
They have just done it again without charge but had to use some silicon to make what they feel to be an adequate seal. Anyone any ideas please.

first-things-first · 7th August 2015, 15:39

Hi

The lower intercooler pipe takes a 51mm silicone pipe. The original's can get porous and so oil leaks through the rubber. I did not see this on mine as there was little oil in that (lower) pipe.

This is more likely to happen on the upper one (which fits to the EGR), as it get recirculated exhaust from the manifold.

I replaced my lower intercooler pipe with silicone and stainless pipe to join.

See here for details :

http://www.the75andztclub.co.uk/foru...d.php?t=222856

Can you confirm this is the one you mean?

The lower one (above) fits directly to the intercooler via a plastic pipe moulded to the intercooler. This may have split in the plastic and is causing the issue?

The upper pipe has a 90 degree plastic elbow that has 2 seals to make a good air seal. This generally causes issues and the oil you describe.

Hope this helps

Andrew

first-things-first · 7th August 2015, 15:43

By the way, to fit the lower intercooler pipe, you just need to move the coolant expansion tank out of the way.

To fit the upper intercooler pipe and seals you can do it from above, but most just take the bumper off (like I did) and should not need the radiator to be move out of way or removed.

See here for upper intercooler pipe and o-rings you need. If this is it, did they fit Viton ones as recommended?

http://www.the75andztclub.co.uk/foru...ad.php?t=74672

jscpch · 7th August 2015, 15:49

Thanks again - will discuss your comments with the garage.

7th August 2015, 14:35	#1
jscpch Regular poster Rover 75 CDTI Club Saloon Join Date: Dec 2013 Location: Benissa/Moraira Posts: 55 Thanks: 1 Thanked 2 Times in 2 Posts	Tube size 2003 cdti. Can anyone advise please. The large diameter black tube from the turbo to the lower part of the oil intercooler - are there different sizes? I live in Spain and had some problems with small regular oil leaks from the pipe which is fitted with two O-rings. Took it to a good English owned garage and they told me that if they fit the O-rings as appears to be correctly that one is still not in the intercooler connection. They did the repair a couple of months ago when they removed the radiator to get good access but it started to leak again after a couple of weeks. They have just done it again without charge but had to use some silicon to make what they feel to be an adequate seal. Anyone any ideas please.

7th August 2015, 15:49	#4
jscpch Regular poster Rover 75 CDTI Club Saloon Join Date: Dec 2013 Location: Benissa/Moraira Posts: 55 Thanks: 1 Thanked 2 Times in 2 Posts	Thanks Thanks again - will discuss your comments with the garage.

7th August 2015, 15:39	#2
first-things-first Posted a thing or two MG ZT Join Date: Jul 2014 Location: Hornchurch Posts: 1,255 Thanks: 176 Thanked 352 Times in 272 Posts	Hi The lower intercooler pipe takes a 51mm silicone pipe. The original's can get porous and so oil leaks through the rubber. I did not see this on mine as there was little oil in that (lower) pipe. This is more likely to happen on the upper one (which fits to the EGR), as it get recirculated exhaust from the manifold. I replaced my lower intercooler pipe with silicone and stainless pipe to join. See here for details : http://www.the75andztclub.co.uk/foru...d.php?t=222856 Can you confirm this is the one you mean? The lower one (above) fits directly to the intercooler via a plastic pipe moulded to the intercooler. This may have split in the plastic and is causing the issue? The upper pipe has a 90 degree plastic elbow that has 2 seals to make a good air seal. This generally causes issues and the oil you describe. Hope this helps Andrew

7th August 2015, 15:43	#3
first-things-first Posted a thing or two MG ZT Join Date: Jul 2014 Location: Hornchurch Posts: 1,255 Thanks: 176 Thanked 352 Times in 272 Posts	By the way, to fit the lower intercooler pipe, you just need to move the coolant expansion tank out of the way. To fit the upper intercooler pipe and seals you can do it from above, but most just take the bumper off (like I did) and should not need the radiator to be move out of way or removed. See here for upper intercooler pipe and o-rings you need. If this is it, did they fit Viton ones as recommended? http://www.the75andztclub.co.uk/foru...ad.php?t=74672