Intercooler to sump pipe does this look normal?

cheechy

A2OC Donor
I'm trying to get a few jobs done over the next couple of days. I've thankfully verified that the knocking noise looks to be the OS outer CV joint which I'll tackle tomorrow...have ordered a small loctite 270 3ml from ecp to avoid future fretting.

Anyhow I'm waffling...i changed the intercooler last year and have noticed I'm getting some oil seepage from the pipe in the picture ...both sides it seems.

My question is around the sump side connection is it meant to look like this or has this been bodged at some point in the cars history?

I've tightened up and realigned the jubilee clips as best as I can but I have my doubts.

Thanks.

Ps i cleaned the oil off just in case you are wondering! :)
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Hi Scott,

If you look at the photos in Sections 13 and 14 of the TDI120 thread, you can see the bracket that holds the lower boost pipe to the sump...

I can see the remains of that bracket in your photos above. It's common that this bracket breaks, due to the stresses caused by the engine tilting during acceleration and engine braking. Without the bracket, though, the lower boost pipe can chafe against the sump.

I'm not entirely sure I've answered your questions, but at least the information is of vague relevance. :)

Cheers,

Tom
 
Also adds stress to the intercooler lower end. Pro boost not an issue, standard Audi folded on end caps the stress turns into cracks that open up into boost pressure loss and limp mode. Said on another thread that the next time I get hold of a broken one, normal engine flexing or pendulum mount bush failure and due to laziness by not opening the clamp before lowering the engine on its mount to replace the cam belt and water pump that I am going to look at improving the design of it even if it is only to replace the half clamps with a Jubilee clip.
As the pipework sits, the join is probably the lowest point from the turbo outlet and oil will pool there.
 
Explains the dodgy looking wire tie that in all honesty looked to be placing lateral force on the pipe that may helped to move the pipe fitting loose slightly.

Thanks chaps I'll try and put in a sensible wire tie or 2 but at least now I know why it didnt quite look right.
 
I would say the OEM unbroken clamp is the way to go. The 2 halves of the clamp hinge around and clip together. When they form the circle it takes up the whole width of the gap you can see in your own picture between the beads on the pipe. But anything to improve a broken bracket may help.
 
So bracket is not available from TPS now so would need to be a Latvia or maybe audi heritage order.

I reseated the pipe, put in 2 new wire ties to the remnants of the bracket and I'm still getting a minor weep from the sump end of the pipe.

Did the pipe originally come with a jubilee clip or a proprietary vw clamp fitting? Just wondering if the jubilee clip us up to the job or the pipe needs replaced? Certainly cant tighten the clip anymore.
 
I've also got a small leak from this hose . The original bracket had snapped but I managed to manufacture a new one from the remaining pieces . Looks like a new intercooler and hose has been fitted recently before I bought the car . The oil level doesn't change much (has used about 700ml of oil in the past 5.5k miles.) I've looked underneath and both ends of the pipe appear secure . Cleaned it all and then after a run it's damp again on the hose and eventually ,once parked for a while , there will be a small drip on the ground from it . Car appears to run fine both performance and economy wise . Short of removing the front end and stripping it all , I'm at a loss as to what is causing it .
 
Oil is getting past the seal in the turbo, eventually the turbo will fail. That clamp sits at the lowest point in the pipework from the turbo to the intercooler and acts as a sump for the oil. All you can do is take the pipe apart and dry out as much oil as you can then when you rejoin the pipes make sure you have an air tight seal.
 
Oil is getting past the seal in the turbo, eventually the turbo will fail. That clamp sits at the lowest point in the pipework from the turbo to the intercooler and acts as a sump for the oil. All you can do is take the pipe apart and dry out as much oil as you can then when you rejoin the pipes make sure you have an air tight seal.
Hmm that doesn't sound good! Car has done 151k miles . Is it best to replace the turbo soon before it completely goes ? There is no smoke from it either at idle or under full throttle.
 
Bearing and seal wear can be terminal. How bad yours is or when it will fail, well that is the unknown. I would be tempted to remove the air outlet pipe from the turbo and have a look at the condition of the blades and also see how much float there is on the shaft. At that point either leave as is for a bit longer or refurb / replace the turbo depending on what you find. Blowing smoke is no indicator of turbo condition.
 
Oil is getting past the seal in the turbo, eventually the turbo will fail. That clamp sits at the lowest point in the pipework from the turbo to the intercooler and acts as a sump for the oil. All you can do is take the pipe apart and dry out as much oil as you can then when you rejoin the pipes make sure you have an air tight seal.
I didn't think there were any seals in a turbo. Oil thrower yes, but oil gets past the thrower when new and into the inter-cooler etc. Some oil in there is normal. Depends how much oil but the if there is too much it could be an oil return problem, turbo could still be good.
 
I didn't think there were any seals in a turbo. Oil thrower yes, but oil gets past the thrower when new and into the inter-cooler etc. Some oil in there is normal. Depends how much oil but the if there is too much it could be an oil return problem, turbo could still be good.
Yeah I was wondering if it really was the turbo. Any turbo diesel I've owned has always had some degree of oil in the intercooler pipes. Even if it was the turbo letting oil past still doesn't explain why it leaks out at this point . Yes it's the lowest point but if sealed correctly surely none should escape . I don't think the consumption is excessive as posted in my previous post . ...more just annoys me.
 
Yeah I was wondering if it really was the turbo. Any turbo diesel I've owned has always had some degree of oil in the intercooler pipes. Even if it was the turbo letting oil past still doesn't explain why it leaks out at this point . Yes it's the lowest point but if sealed correctly surely none should escape . I don't think the consumption is excessive as posted in my previous post . ...more just annoys me.
My car is on stands at the moment and I have just today connected those pipes. I have a AMF engine, can get under there and take a few pictures, I have no leaks, ran it to test it.
Edit: my response may be rubbish, we have a thread within a thread, but happy to take pictures if that helps anybody.
 
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Bearing and seal wear can be terminal. How bad yours is or when it will fail, well that is the unknown. I would be tempted to remove the air outlet pipe from the turbo and have a look at the condition of the blades and also see how much float there is on the shaft. At that point either leave as is for a bit longer or refurb / replace the turbo depending on what you find. Blowing smoke is no indicator of turbo condition.
I was always under the impression that blue or greyish smoke can be one of the tell tale signs of turbo issues ( could also be other things such as valve stem oil seals etc ) . Quick Google seems to confirm that a worn turbo is likely to cause some sort of smoke from the exhaust. Think I'll just strip the front end at some point and have a look where the hose connects to the intercooler to see if there is anything obvious. Given the car is still performing perfectly fine I doubt it is the turbo. Thanks everyone for the advice . Sorry to hijack a thread ( it was kind of related to the original point ?)
 
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