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I have a 2.2 hdi 03 coupe and have fluid leaking out of the intercooler piping and when I took the trottle body out and checked the inlet manifold it was coated with a tar like substance , very thick and gooy. when I further dissassembled the piping it was everywhere but thinner as I got farther away from the inlet mani. I found a crack in the plastic pipe that goes under the engine which is leaking liquid. It doesn't smell like diesel and feels like oil. Also the plastic joint at the radiator on the right side (from driver's position) is leaking the same fluid but much worse. this is where the MAP sensor in connected. Obviously the leaks are not to be there but is the tary substance normal ? Is the intercooler part of the radiator or seperate but appached to it ?
One other question anyone know where the relay for the glow plugs is I just can't find it , PP2000 says it is shorted ?
thanks for any help , this is a great forum and has been lots of help to me and I am sure others

Mine is more or less the same, as regards the 'fluid' (which is oil). Apparently it's normal for a little to get past the oil seals in the turbo & then to be blown through the intercooler and finally into the inlet manifold. Some will also come via the crankcase & cambox breathers into the inlet tract.

In extreme cases it can be terminal, (though I've never heard of one with a Peugeot), where the quantity of oil ingested is great enough to fuel the engine, which can race to destruction.....

I think you would notice a sharp increase in oil consumption long before this happens.

My car has signs of leakage from most of the same spots, (though it does sound like you may have a cracked boost pipe under your sump).

Finding the biggest concentration at the bottom of the intercooler is also logical, as it will start out largely as vapour and condense at this point. I think what you're seeing is quite common.

The glowplug relay mesage also seems to be a common glitch - if it's starting easily, I wouldn't worry about this one either. IIRC the glow plug connector on exboyracer's car has been snapped off for a couple of years and his starts fine.

A bit of topic but my mate services Landrovers and it is part of the service schedule on the td5's to remove and flush the intercooler out,i had a Ford Ranger(mazda) as a company vehicle a few years back and that had a split intercooler hose and oil leaked from it so i think it's normal as doggy says to have oil in the turbo system although not excessive.

thanks for the replies, I was thinking the same , that there would be some of this oil collection. But I have washed off the leakage at the connection front right of radiator twice and only done 800 miles , so I am wondering if the plastic couplings of the intercooler/radiator may be cracked . Ah it looks like an aweful lot of work to dismantle it.

All it is is vapourised oil... its due to the fact that the oil gets so hot and vapourises and makes its way past the seals.