3 problems with my 406 estate 2L hdi 110

[alexpogg]

Hi, I have a 1999 406 estate 2.0 l 110hdi with 100k on the clock, i am new to this site and found it really useful just browsing through, i didnt realise that the second button on my keyfob actually deadlocked the car and alarmed it !, you live and learn.
The 3 problems i have are as follows, No 1 problem.... the clutch only bites when the pedal is near enough at the top, does this mean a new clutch or is their an adjustment ? No 2 problem....there is a small radiator to the right hand side of the main radiator, i believe that this is the intercooler, it has oil around the bottom of it so is obviously leaking, so i need to change it i think, is it a big job ?, would i need to drain the oil and do you know if this is an expensive item to replace and are reconditioned ones available ?
No 3 problem is a little hard to explain but here goes.......if you open the bonnet and look to the far left hand side of the engine compartment near enough up against the bulkhead you will see what looks like a bronze coloured valve with a hollow centre (best description i can give), just behind this "valve" is a large black rubber or plastic pipe (against the bulkhead) and i have noticed that when you rev the car it gives out a fine mist of either oil or fuel and it has left a considerable residue on the pipe,i have searched the haynes manual but still cannot locate the item, i know its a bit vague but does anyone know what it is.
Thanks very much for taking the time to read this, hope you can help.

[djp30djp]

Hi, clutch bites near the top is normal, all mine are the same - it's hydraulic self adjusting.
The intercooler does not have any oil in it - or shouldn't.
I don't know about the other thing because it sounds like an add on, where does the other end of the pipe go?

[alexpogg]

hi, i presume the intercooler is a type of radiator (sorry not very mechanically minded) there is definately oil at the bottom of it, i will have a closer look in the morning at the valve i mentioned, cheers for your advice, i want to keep this car you see as i am told that 100k motorway miles is nothing for this engine.

[steve_earwig]

If you've a digital camera a picture paints a thousand crummy descriptions

[alexpogg]

i will take a photo in the morning, thanks again, you have been really helpful.

[GeordieBoy]

My Intercooler is the same, its not filled with water, its cold air I beleive, so the leak is proberly condensation.

Clutch sounds fine, aslong as its not slipping. That said mine never slipped and it suddenly went changing from 1st to 2nd.

[mikey s]

oil in the intercooler is perfectly normal. its due to them using a closed breather system due to emmisions regulations.

[puggy]

Hi there ... i have the same intercooler problem with my hdi, it is only air that
passes through it but it is quite normal to get a small amount of oil residue in the
system. Mine leaks where it fits into the plastic bottom, was quoted around £200
for a new one by the main stealers (dearer than a rad ) look on the net or
if like me you have a radiator specialists near you contact them, mine said when
i take it off pop it along and in a couple of mins they will be able to tell if it can be
done and will be nowhere near as expensive as a new one

[Welly]

Clutch bite is normal.

The intercooler will contain small amounts of oil which 'carries over' in the airstream from the compessor side of the turbo. Remove the bottom large air hose from the IC and check how much oil is there. If *loads* of oil comes out then this is a problem from the turbo, if it's just a small amount it is normal. If the oil is seeping through the aluminium cooling fins then there is a small hole in the intercooler from a stone chip perhaps and should be replaced, if the oil is weeping from the hose connection then tighten the clip as they do work loose.

The bit on the bulkhead is the EGR valve, just below this there is a large plastic pipe about 50mm diameter. This is the air intake pipe to the turbo, it has a bit of silver heat tape on it, it may be split for some strange reason. When you rev the car is goes from being in a vacuum state to a possitive pressure when the dump valve discharges into it, I've never heard of this problem. The Turbo's are pretty bullet proof on HDi's. The only other pipes around there are vacuum lines and one coolant hose.

[mbell666]

I thought i had oil coming out of my intercooler. It turned out just to be very dirty black water/mud.

As you drive along the intercool will collect dirt, when it rains it will collect water which is forced through the cooling fins. When it comes out the other side it normally looks like oil, but it in fact very dirty water.

Give it a good clean, you probably find it stays clean until next time it rains (so about 15 mins at the moment)