Intercooler failure

Nice work Robert !!! Fantastic job. Very enterprising and a challenge for any welder, but what a great outcome !! Brilliant !!
 
I've checked my Intercooler today as i'm suffering the 4th/5th gear syndrome. There is a light mist of oil right at the bottom of the Intercooler but not anywhere up the fins, is this normal?

I haven't found any loose hoses except one of the 3 small hoses that sit under the scuttle tray to the right middle of the car as you look in from the front, had become detached so i reconnected it, and also sprayed the MAF with contact cleaner as suggested in another post, seems ok but the true test will be the commute tomorrow morning?
 
Without seeing it in person or a pic its hard to give an absolute answer but if the oil is fresh it must have come from somewhere-so i would say yes your intercooler is sounding like its got a leak. If the leak is towards the bottom i would say it may be coming from the lower pipe area. The loose pipe under the panel could that be where someone has blocked off the vac line to the EGR?
 
Finally stopped raining so I've managed to take a picture.

55fl6p.jpg


Looks dry to me no signs of oil on it.

Also I notice a bolt in a pipe just below the central air intake in the middle of the car, does this mean my EGR has been blocked off

300sb4y.jpg
 
Yes I would say that's the egr vac line blanked. The intercooler looks fine so I would be checking the small pipes for cracks or even one come off. Just one other point - has it had a fuel filter at the service points ? As an old fuel filter can cause many an odd issue. Cheers Mike
 
Fuel filter was replaced this time last year as were all the other filters. I'm due an oil change in the next 400 miles, so I will have a look from underneath at the pipes. All the other pipes from above have been checked.

I've had a 10 mpg drop in economy which is very disconcerting.
 
trufflestu said:
Fuel filter was replaced this time last year as were all the other filters. I'm due an oil change in the next 400 miles, so I will have a look from underneath at the pipes. All the other pipes from above have been checked.

I've had a 10 mpg drop in economy which is very disconcerting.
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Guess you found the culprit, what was wrong? Always handy to keep an eye out for something else. :)
 
Yes, so many fault threads end in "mid-air" unresolved. Every member should be encouraged to round off a fault thread describing the cure found for the fault -This will help others in the future.

Andy
 
I think I had a dodgy batch of fuel from one of the well known Oil company subsidiaries, but unfortunately haven't been able to prove it.

Now running back at normal levels for me on the MPG
 
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