CDT Slight powerloss turbo intercooler leak found

Jules · 26th June 2007, 09:18

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

This shows mopping out oil pool & the lip that holds the lower ring in place

New Viton rings fitted oh & our new tripple horn setup

A bad case of swelling seals & certain turbo hiss!

Ti Rich · 26th June 2007, 19:02

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.

Jules · 26th June 2007, 21:18

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

Roverron · 1st July 2007, 18:19

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!

Ti Rich · 2nd July 2007, 21:15

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?

martin1973 · 4th July 2007, 10:03

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?

Jules · 4th July 2007, 10:13

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

Jules · 4th July 2007, 10:23

Quote:

Originally Posted by andycolm

Just an update to say its now completed and road tested.
I had to cut the O ring down as I didnt have a new one handy however this seems to have worked... maybe a bit of PTFE tape around the O Ring would help even more.
Refitted and took it for a test drive which seems to have cured the whistle and got the power back.
You should be able to remove the pipe easily without taking the bumper off, if the jubilee clip is accesible from the inside, the 8mm bolt is removable from the engine compartment and then its a simple matter to pull the plastic pipe from the 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

martin1973 · 4th July 2007, 14:25

Quote:

Originally Posted by julesbass

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

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

pondweed · 4th July 2007, 15:42

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.

26th June 2007, 09:18	#1
Jules This is my second home ZT 260 SE Twilight and 10 other 75 ZT's :O Join Date: Jan 2007 Location: Conwy NORTH WALES Posts: 11,094 Thanks: 512 Thanked 1,116 Times in 763 Posts	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 This shows mopping out oil pool & the lip that holds the lower ring in place New Viton rings fitted oh & our new tripple horn setup A bad case of swelling seals & certain turbo hiss! __________________ [SIGPIC][/SIGPIC] Newbies do now!! 1. Plenum drains..all 3 or 4 year dependent 2. Cooling fan..All speeds functioning 3. Bonnet cable divider block Last edited by Jules; 4th September 2008 at 08:28.. Reason: Add part number

26th June 2007, 19:02	#2
Ti Rich Gets stuck in Audi A6 TDi 175 Join Date: Nov 2006 Location: Dudley Posts: 572 Thanks: 0 Thanked 3 Times in 2 Posts	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. __________________ CD(Ti Rich) Audi A6 C7 TDI - zzzzzzzzzzzzzz, so boring!! BMW 330d M-Sport - Gone and missed ZT CDTi, gone but not forgotten!

26th June 2007, 21:18	#3
Jules This is my second home ZT 260 SE Twilight and 10 other 75 ZT's :O Join Date: Jan 2007 Location: Conwy NORTH WALES Posts: 11,094 Thanks: 512 Thanked 1,116 Times in 763 Posts	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 __________________ [SIGPIC][/SIGPIC] Newbies do now!! 1. Plenum drains..all 3 or 4 year dependent 2. Cooling fan..All speeds functioning 3. Bonnet cable divider block

1st July 2007, 18:19	#4
Roverron Gets stuck in Rover Join Date: Nov 2006 Location: Tarbert Posts: 980 Thanks: 0 Thanked 19 Times in 9 Posts	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! __________________ [SIGPIC][/SIGPIC] Click to visit my website Ron on Twitter MyFacebook page

2nd July 2007, 21:15	#5
Ti Rich Gets stuck in Audi A6 TDi 175 Join Date: Nov 2006 Location: Dudley Posts: 572 Thanks: 0 Thanked 3 Times in 2 Posts	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? __________________ CD(Ti Rich) Audi A6 C7 TDI - zzzzzzzzzzzzzz, so boring!! BMW 330d M-Sport - Gone and missed ZT CDTi, gone but not forgotten!

4th July 2007, 10:03	#6
martin1973 Loves to post MG ZT Join Date: Jan 2007 Location: Kendal, Cumbria Posts: 456 Thanks: 0 Thanked 0 Times in 0 Posts	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?

4th July 2007, 10:13	#7
Jules This is my second home ZT 260 SE Twilight and 10 other 75 ZT's :O Join Date: Jan 2007 Location: Conwy NORTH WALES Posts: 11,094 Thanks: 512 Thanked 1,116 Times in 763 Posts	Wrong pipe martin. That pipe you can see is the outlet from intercooler. __________________ [SIGPIC][/SIGPIC] Newbies do now!! 1. Plenum drains..all 3 or 4 year dependent 2. Cooling fan..All speeds functioning 3. Bonnet cable divider block

4th July 2007, 15:42	#10
pondweed This is my second home Waiter, Waiter! I seem to have a Roomster in my drive... Join Date: Nov 2006 Location: Sussex Posts: 3,268 Thanks: 0 Thanked 1 Time in 1 Post	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.