Air doser / intercooler cleaning.

[GingerMagic]

As the title suggests, I have very oil deposits all around the air doser and the intercooler pipes etc. Air doser is disconnected.

There is oil around the doser vacuum parts

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This is the oil I see when I removed the intercooler top pipe

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This is the view inside the intercooler

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I also think there may be a leak in the bottom intercooler hose as there is a puddle of oil on top of the pipe - like it has sprayed up and then pooled after hitting the pipe above

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There is lots of mess under the bottom pipe too.

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Can all these parts be removed and cleaned, which I hope will let my car breath easier and not be so smokey..?? Also, would all this residue be affecting the injectors etc?
After driving Doggys car I realise how much better mine could be..

What would be the best way to clean said parts, maybe a soak in a tub of petrol the flushing out..?

[jonny81191]

Yes, they can all be removed, but if there's a lot of oil in your intercooler system, it could be a sign of turbo oil seals failing. Do you have a catch tank fitted?

[jonsowman]

Kelv, seeing as you're de-FAP'ed and de-EGR'ed you could consider fitting Nico pipes?

Removes a load of that boost pipework, the dosers, etc.

[GingerMagic]

I don't know about the catch tank, is that a sort of vapour tank some people talk about?

I was offered a set of Nico pipes and I nearly bought them but will do more research first as some coupes with the pipes fitted have had head gasket complications...

[Doggy]

I think all you're probably seeing here is the oil carry over from the breather, which is drawn into the 'elephant hose' between the air box and the turbo. When the charge is cooled by the intercooler, the oil vapour condenses and this is the result. Both of my 2.2's looked much the same, if anything the current 110k example shows more oil round the bottom of the intercooler and hoses than the original dogmobile did after lots more miles!

If you think about it, you can only be losing whatever quantity you have to replace by topping up. Both of mine needed typically 0.5 to 1.0 litres between oil changes or between 5 & 10k miles/pint, which doesn't give me any concerns.

It's unsightly and I'm tempted to dabble with an oil catch tank, but only one where the oil is separated from the breather airstream, which then goes back into the induction system, as Pug intended. This might significantly reduce the oil carry over, making cleaning up the mess more worthwhile, since it might not return for a long time. Downside is you have to check / periodically empty said tank, (once you find somewhere to put it).

I could be wrong and cleaning it out may help, but I think mine's every bit as oily as yours.

[Doggy]

Just a thought, Kelv.

Your egr blanking plate couldn't be leaking, could it?

[GingerMagic]

How would a leaky blanking plate affect the engine? I kind of understand how the EGR system works by from breathing in its own soot, but don't know what happens if there is air getting in or out the blanks.....
I will look for signs of leaks somehow but not sure how to identify them, but I will be armed with something to tighten them up just in case.

Not sure what else could be slowing me down - I know brakes are binding just a tiny amount but not enough to hold back that much power

Thanks again Eric for the map, the 180bhp is a much more refined unit and can comfortably get 45mpg without driving like an octogenarian, the 200bhp map was less economical, a poor performer when pootling along but much quicker when pushed.

Very happy with the figures but still a little perplexed by the difference between our cars.

I'm clutching at straws like a scarecrow watching porn.......

[Doggy]

How would a leaky blanking plate affect the engine? I kind of understand how the EGR system works by from breathing in its own soot, but don't know what happens if there is air getting in or out the blanks.....

A problem at the inlet manifold end could give you a boost leak, e.g. loss of boost coupled with too much fuel. Maybe give you a lack of grunt and lots of smoke.

[GingerMagic]

Ohh, I will definitely be checking that then, I hope this is the answer.....

[jonsowman]

I'm clutching at straws like a scarecrow watching porn.......

[GingerMagic]

Just a quick question, has the blanking plate got any sealant behind it which I will need to replace, also I guess the inlet one is the one by the doser.....
I suppose that was two questions...

[Doggy]

Just a quick question, has the blanking plate got any sealant behind it which I will need to replace, also I guess the inlet one is the one by the doser.....
I suppose that was two questions...

I guess it should have some sort of seal, probably quite safe to use instant gasket, (if it goes anywhere it should be forced outwards). You may find the blanking plate's not stiff/strong enough to seal properly, in which case knock up something sturdier.

...and yes it is the one by the doser

[GingerMagic]

Well I checked the blanking plate and it is solid - Al from the coupe forum did it when doing my de-fap and I know he is thorough and uses quality materials.

However, I was revving the engine today with my head in the engine bay and I spotted the black pool of oil moving under revs, the pool on the bottom hose that is, and also the bottom of the intercooler itself was producing little oily bubbles.....Is this normal. I have a chance of a replacement intercooler and MAP sensor so I will give these a go if I can get hold of them.

[oldskoolskool]

going by your 'bubbling comment' it sounds like you have a leak in the intercooler, so if you have the chance of getting another go for it.

Also the air-dossers always seem to leak on higher mileage cars (if oil can get out air definitely can) so Nicowico pipes are a worth while investment if only to keep oil of the block (they only reduce the inlet air temperature slightly at set points so would not have an impact on the head gasket, egr blanking and re-map's are the highest risk modifications to the head gasket as they would raise the combustion temperature significantly).

also when cleaning the hoses/intercooler you should inspect the small hose that runs from the intercooler to the map sensor as it is exposed to this oil and deteriorates causing it to 'ballon under pressure, and leak slightly (you will probably find that end of the interccoler covered in oil too).

[Doggy]

It'd be a cruel twist if it was your intercooler, since the one from your donor car's is on my bro's.....

From the way your car has lost it's 'edge' and is a bit smokey, a boost leak somewhere fits the bill. Hope you track it down painlessly Kelv.