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Old 28th March 2021, 10:12   #31
Arctic
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Richard as above if the intercooler hose, is swollen and sticky to touch change it, double check the intercooler O-rings, check pipe for any tiny split, make sure all jubilee clips are tight.

Have ever cleaned out the manifold EGR MAP sensor on your car yet ?

These can also be used for the two part intercooler hose you just need to cut it.
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Old 28th March 2021, 10:14   #32
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If it's drawing air in from somewhere that can cause it to smoke i've been told.


Black smoke is mainly due to a fuelling / air problem, either excess fuel being injected for the amount of air drawn in or insufficient air drawn in for the amount of fuel injected, both amount to the same thing an over rich mixture.


If you had a leak in the intercooler pipework, air would be blown out, not sucked in, it is at whatever pressure the turbo is producing.


When flooring a turbo diesel from low revs or idle there will nearly always be a puff of black smoke initially, this is due to the amount of fuel your foot is asking for being injected almost instantaneously before the turbo has time to spool up to pressure, the exhaust returns to normal when the fuel to air ratio is correct a second or two later.


If you keep your foot down does the thick black smoke continue, or does it settle to a normal exhaust ?



You need to check the whole air side of the system from air inlet through to the inlet ports for restrictions, also that the turbo pressure and air flow is within spec.


Intercoolers can be partially blocked, rare but not unknown.


Next is to check fuel side to ensure that the fuel pressure is correct and that the injector dwell time is as it should be.


Another odd one is a partially blocked silencer that causes an increase in exhaust back pressure
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Old 28th March 2021, 11:36   #33
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Quote:
Originally Posted by Ducati750cc View Post
If it's drawing air in from somewhere that can cause it to smoke i've been told.


Black smoke is mainly due to a fuelling / air problem, either excess fuel being injected for the amount of air drawn in or insufficient air drawn in for the amount of fuel injected, both amount to the same thing an over rich mixture.


If you had a leak in the intercooler pipework, air would be blown out, not sucked in, it is at whatever pressure the turbo is producing.


Quote:
When flooring a turbo diesel from low revs or idle there will nearly always be a puff of black smoke initially, this is due to the amount of fuel your foot is asking for being injected almost instantaneously before the turbo has time to spool up to pressure, the exhaust returns to normal when the fuel to air ratio is correct a second or two later.


If you keep your foot down does the thick black smoke continue, or does it settle to a normal exhaust ?



You need to check the whole air side of the system from air inlet through to the inlet ports for restrictions, also that the turbo pressure and air flow is within spec.


Intercoolers can be partially blocked, rare but not unknown.


Next is to check fuel side to ensure that the fuel pressure is correct and that the injector dwell time is as it should be.


Another odd one is a partially blocked silencer that causes an increase in exhaust back pressure
My tourer does not put out any smoke even if i boot it, which i do at least once a week i drive it like i stole it,

Richard
you could always contact Jamie, and ask him for an health check with his full fat T4, i am sure he would come to you or you to him.
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Old 29th March 2021, 08:00   #34
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I've replaced the top intercooler hose, the nice easy to see and get to one,
I was told by someone at the first Nano meet it was mullered, so I bought a new one pretty quick.

The inlet manifold and EGR has been cleaned out and I fitted new neoprene seals at the same time.

I've not replaced the intercooler seals as I was told that it was nice and clean around the pipe, and there would be residue around the area if they needed changing.
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Old 29th March 2021, 10:07   #35
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Originally Posted by Odd Job View Post
I've replaced the top intercooler hose, the nice easy to see and get to one,
I was told by someone at the first Nano meet it was mullered, so I bought a new one pretty quick.

The inlet manifold and EGR has been cleaned out and I fitted new neoprene seals at the same time.

Quote:
I've not replaced the intercooler seals as I was told that it was nice and clean around the pipe, and there would be residue around the area if they needed changing.
Double check the intercooler O-rings, remove the intercooler hose then remove the bend.

Replace the O-rings with Viton ones.
1

2

3

Then pull the bend out of the intercooler.

once removed check that the old O-ring is not stuck in the intercooler,
4

5

The O-ring on the end of the bend usually swells therefore does not seal, you can see the form this photo the difference.

6

7

Clean in the intercooler hole with a rag, then fit new O-rings to the bend, add a little rubber grease to the O-rings and then refit the bend making sure it is fully pushed home, you should hear a little thud as it seats correct.
8

9

replace the 8mm bolt, then fit the intercooler hose.
10

The above only takes about 20 minutes and about £3 for the O-rings, so worth doing in my opinion.
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Old 29th March 2021, 11:23   #36
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Many thanks Steve,

I've got some of those seals ( somewhere ) I had it in my head the front bumper needed to come off for some reason, but as I can see it's "just" a case of bending my back!

I'll have a dig around and find the seals out and have a go one evening.
I'll obviously report back to if it's made any difference or not.

Only thing I think I'm lacking is rubber grease!
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Old 29th March 2021, 11:56   #37
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Quote:
Originally Posted by Odd Job View Post
Many thanks Steve,

I've got some of those seals ( somewhere ) I had it in my head the front bumper needed to come off for some reason, but as I can see it's "just" a case of bending my back!

I'll have a dig around and find the seals out and have a go one evening.
I'll obviously report back to if it's made any difference or not.

Only thing I think I'm lacking is rubber grease!

I did the o-rings on mine too, so... err... you've got my number.
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Old 29th March 2021, 13:19   #38
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I did the o-rings on mine too, so... err... you've got my number.
Have you any rubber grease please?
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Old 29th March 2021, 14:27   #39
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Oh.

Sorry I missed out on tea making duty.

If Paul can't find his rubber grease (oh, er, misses... ) I've got loads so I can pop some in a container and post it up if needed.
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Old 29th March 2021, 18:37   #40
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Well,

I've searched the house out, and cant find the intercooler rings.
I'm intending to fleabay myself some more this evening, but,
the hoses going into the intercooler are perfectly "dry" no oily residue anywhere.
I've tried to take a photo, but cant get my camera-phone in the right place to get a shot.

I will replace the seals as I need to start somewhere, but if the area is completely oily / soot free, does that mean the seals are still doing their job?

Many thanks.
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