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Oil on bottom of intercooler

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Catch22

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Discussion starter · #1 ·
From what I can see the sump guard area is wet with oil and there is oil on the IC. From what I have read on here it's a common fault where the IC splits and oil leaks out due to the breather system.

The engine has no leaks and neither does the power steering as the pipes are dry.

I'm right in assuming it pretty much has to be the intercooler? I've got 3 months warranty from the dealer I bought it from so hopefully it should be sorted.
 
Discussion starter · #3 ·
Had the grill off today and did the soapy water test on the intercooler with engine running, and sure enough its bubbling on both sides.

The dealer is ordering a new intercooler under the warranty. I've asked if they will let me fit it as it's a pain driving back to them and getting a lift back and they agreed.

From the look of it, it's a bumper off job. Anything else I should know about before taking it on?

Cheers,

Wayne.
 
#4 ·
Catch22 said:
Had the grill off today and did the soapy water test on the intercooler with engine running, and sure enough its bubbling on both sides.

The dealer is ordering a new intercooler under the warranty. I've asked if they will let me fit it as it's a pain driving back to them and getting a lift back and they agreed.

From the look of it, it's a bumper off job. Anything else I should know about before taking it on?

Cheers,

Wayne.
Click to expand...
Nothing to worry about really straight forward and yes bumper off.
 
Discussion starter · #6 ·
Intercooler arrived!!

I now have the replacement intercooler kit, which comes with the foam seals and a new metal undertray. No sign of any seals for the elbows that connect to the hoses. What type of seal is it? O-ring, paper gasket or just gasket sealer? I'm doing the job on Saturday so need to make sure I have all I need.

Cheers for any help.

Wayne.
 
#7 ·
Catch22 said:
I now have the replacement intercooler kit, which comes with the foam seals and a new metal undertray. No sign of any seals for the elbows that connect to the hoses. What type of seal is it? O-ring, paper gasket or just gasket sealer? I'm doing the job on Saturday so need to make sure I have all I need.

Cheers for any help.

Wayne.
Click to expand...
Been a while since I did mine but I dont remember any gaskets so I must have used gasket sealer which I would have had in the garage.
 
Discussion starter · #8 ·
will2020 said:
Been a while since I did mine but I dont remember any gaskets so I must have used gasket sealer which I would have had in the garage.
Click to expand...
Gaskets between the intercooler and elbows which I reused and treated with some loctite 5970. The elbows were corroded where they meet the hoses, which must have been creating an air leak along with the leaking end tanks and the bulging centre of the core. The core itself was bowed and looks like it's happened due to pressure? The aluminium on the tubes was very thin and easy to poke a hole in.

Anyway, all is now well and it runs better and goes like stink. I'm wondering if it's already been remapped?
 
#9 ·
Jumping on this thread. I started my own but this one caught my eye. My local garage abandoned my MOT due to the amount of oil on my undertrained and IC.
I have no power issues and the truck runs great, I removed the grill for a better look tonight and the whole bottom of the IC is soaked in oil, but it’s worse on the passenger side.
Now, I worry that this amount of oil shouldn’t be there in the first place to leak, and it should be noted that I am losing oil at about 3l a year.
Would this still hint at an IC issue or more likely turbo despite the lack of issues with power.
Photos attached.
Thanks
Nick
 

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mrw27
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