Jules
16th September 2007, 16:17
DIESEL INTER COOLER O RING MODIFICATION.
As mentioned on one of my previous threads, entitled CDT slight power loss This only affects the earlier design inter cooler. They were redesigned round about 53 Reg when they also did away with the Secondary fuel pump near the battery.
Bumper and Slam panel removal I'm afraid. Very awkward without:(
I have had a few of these lately and on low mileage diesels too, so I think there's 2 problems here
There is a design fault here with the inter cooler O rings and the way the plastic elbow is secured.
1. Incorrect rubber compound (we have had cars in with mileages as low as 30K with these O rings swelling)
2. The elbow does not seat deep enough into the inter cooler housing. Only one 8mm head bolt holds it in. Even with new O rings the outer one is visible with everything tightened up. :
I had to do a modification in a hurry for a customer so there is probably a better solution but this was better than nothing:
If anyone comes up with a better solution don't forget to post it!
Using 2 X Jubilee Clips and some aircraft wire locking, it stops the elbow from blowing out under full turbo pressure
One oil ring will have spewed out of the top, the other falls down into the inter coolerhousing. (easily retrievable)
I would try and source some better quality O rings than the OEM ones, try a hydraulics company
The OEM Part No is: PYX100320 and are of dubious quality.IMHO
http://www.the75andztclub.co.uk/forum/imagehosting/81146ed4fee4a3a6.jpg
http://www.the75andztclub.co.uk/forum/imagehosting/81146ed4fef72486.jpg
http://www.the75andztclub.co.uk/forum/imagehosting/81146ed51a95b813.jpg
http://www.the75andztclub.co.uk/forum/imagehosting/81146ed503f7d053.jpg
As mentioned on one of my previous threads, entitled CDT slight power loss This only affects the earlier design inter cooler. They were redesigned round about 53 Reg when they also did away with the Secondary fuel pump near the battery.
Bumper and Slam panel removal I'm afraid. Very awkward without:(
I have had a few of these lately and on low mileage diesels too, so I think there's 2 problems here
There is a design fault here with the inter cooler O rings and the way the plastic elbow is secured.
1. Incorrect rubber compound (we have had cars in with mileages as low as 30K with these O rings swelling)
2. The elbow does not seat deep enough into the inter cooler housing. Only one 8mm head bolt holds it in. Even with new O rings the outer one is visible with everything tightened up. :
I had to do a modification in a hurry for a customer so there is probably a better solution but this was better than nothing:
If anyone comes up with a better solution don't forget to post it!
Using 2 X Jubilee Clips and some aircraft wire locking, it stops the elbow from blowing out under full turbo pressure
One oil ring will have spewed out of the top, the other falls down into the inter coolerhousing. (easily retrievable)
I would try and source some better quality O rings than the OEM ones, try a hydraulics company
The OEM Part No is: PYX100320 and are of dubious quality.IMHO
http://www.the75andztclub.co.uk/forum/imagehosting/81146ed4fee4a3a6.jpg
http://www.the75andztclub.co.uk/forum/imagehosting/81146ed4fef72486.jpg
http://www.the75andztclub.co.uk/forum/imagehosting/81146ed51a95b813.jpg
http://www.the75andztclub.co.uk/forum/imagehosting/81146ed503f7d053.jpg