CDT Slight powerloss turbo intercooler leak found
 

While I had the bumper off our very own CDT last week renewing fan motor, adding a 2nd horn and while at it, flushed all the smelly bacteria out of the washer bottle, I noticed an oiled area around the inlet elbow pipe to the intercooler ( RHS as looking from front)

Closer inspection revealed a swelled up protuding O ring!

This would explain the slight hiss sound and slight powerloss.
This elbow pipe is on the output of the turbo to the inlet of intercooler so is under pressure
On dismantling elbow (1 bolt), I found 2 O rings one split and fallen in to intercooler!


There should be 2 o rings according to diagrams. The lower one is usually found lurking at base of intercooler!!

Dimensions of O ring are approx 48mm by 3.5mm. OEM ring still available. Part No PYX 100320
I suspect these original seals are not as Oil /diesel proof as they could be and probably made of Nytrile rubber . See pics Universal Rings from a kit will NOT fit You need OEM ones or better aircraft spec'd ones!
(see here)http://www.the75andztclub.co.uk/foru...ad.php?t=24863

Access to the O ring seals & this elbow (pic centre) involve front bumper removal & passenger side headlamp
http://www.the75andztclub.co.uk/foru...c2b2135642.jpg
http://www.the75andztclub.co.uk/foru...c2b21af749.jpg
This shows mopping out oil pool & the lip that holds the lower ring in place
http://www.the75andztclub.co.uk/foru...c2b220dbf2.jpg
New Viton rings fitted oh & our new tripple horn setup
http://www.the75andztclub.co.uk/foru...c2b5937dc0.jpg

A bad case of swelling seals & certain turbo hiss!
http://www.the75andztclub.co.uk/foru...0d08faba26.jpg

http://www.the75andztclub.co.uk/foru...0d09078dc5.jpg

Good info - mine is wet in that area too.

How easy is it to gain access to the intercooler? I would like to take mine off and clean it.

Well my bumper and slam panel were both off anyway so a doddle to get at.

Having looked at the job fully assembled you just maybe able to get at the 6mm bolt with 8mm hex socket that secures the inter cooler elbow.

Even if you can't get the jubilee clip loose at the other end, it might not matter as the rubber hose will flex enough for you to change that O ring.

Good luck, let us know if it possible without full frontal dismantle.

Jules

This seems to be quite a common occurence and something all owners should keep an eye on.
It may weel explain why some owners seem to get smoke with a Tu3 or Synergy fitted, whereas others don't.

Ron

PS KIA SEDONA 2.9CRDI + TU3K = one quick people carrier! (or taxi as in this case!)
So that's another vehicle to add to my list of TU3 successes!

Mine has oil around the intercooler inlet so I will have a better look. Do we know the part number guys? and can it be fitted without taking the bumper off?

Only had a quick glance under the bonnet as it was raining, but if im looking in the right area (top RHS of radiator, pipe is behind headlamp cover) mine is a flexible rubber hose rather than a rigid moulded plastic pipe as per the photos..... Or am I looking at the wrong pipe?

Wrong pipe martin. That pipe you can see is the outlet from intercooler.

Attention guys!!
The correct OEM O ring Part no: PYX 100320 however I would recommend fitting Viton O rings instead of the OEM ones!
Viton spec are higher temperature and Fuel resistant. It seems the OEM rings are not!

As the intercooler and seals are under pressure from the turbo of at least 1 Bar or 14 PSI

Left a bit? right a bit? back a bit? could you direct me to the correct pipe please

I'll plump for looking at the other end of that partic. rad!
The intercooler is only like a rad with one inlet and one outlet? Just make sure you id all the other rads ((i.e. cooling one and aircon condenser) and check they have their respective inlets and outlets and you should get there.