Collapsed intercooler exit pipe and black smoke at high rpm

[trnx]

Could also be dpf blocked. Not sure. But forscan wint let me do dpf forced regen. Again… had fuel tank filled and forscan setup. But just fails to complete. Think the new forscan blinker obd cable will help. Will keep you updated. Would you suggest checking turbo before flushing intercooler? What is easier? Never done either. Could it be intake gunked up from previous turbo failure in the past? I just don’t like the look of taking that off and cleaning it. Looks complicated.

I have done all the wrong things in the past. Starting it without letting glow plug go out. Running it low on diesel. Unplugging EGR valve fkr quite a while as it ran better. Now reconnected.

It’s an 18 year old van. So maybe it’s time it went to the scrap heap in the sky. I know one thing. It would be worth a fortune in scrap. lol.

On the forscan image it shows 2008 vehicle - no DPF.
Better to show info' re' the vehicle - can be put into the signature for the forum posts.
Better to sort one thing at a time - fix it - get it right - move onto the next thing.
There's posts re' cleaning the intercooler and inlet system pipes, checking the turbo.

[metalworker0]

** air intake system spray

Lazy way of doing it .. sometimes works on the egr by wetting gunge build up, releasing a stuck egr .as a temporary measure.. nothing else

pull whole boost pipes .. inlet pipes and and intercooler off

and from a previous post i made here:

To perform a a boost pipe and intercooler service .

But if you ask me ...my personnel opinion...
The following is a a job that should be done on these vans at least every couple of years or 15,000 miles, what ever comes first.

I would be taking all the pipework off including intercooler ..and giving it all a really good clean inside and out ..during the clean you can inspect each piece individually for damage or cracks..or rubber sealing gaskets ..ripped, torn , deformed etc ...
What you will find ------- lots of oily gunge..
I use very strong solution of biological washing powder...sort of 1 cup full to every pint of boiling water ..intercooler has to be REMOVED..it will probably take 2- 3 pints

Block one end . Rags, towel, plastic bag and elastic band ..pour it in. then let stand for five mins ...shake it ..pour it out and flush with hose.

You could use paraffin , Jizer or petrol ..but that would be far more expensive than cheap Lidl / Aldi or Home Bargains washing powder.

Other people with the same problems (not many here) install "catch cans" between the PCV (right hand of cylinder head ) and the boost pipe. which will also lessen the accumulation of gunge in the EGR and inlet manifold which can cause problems after a while.


all the best.mark

[Bat135]

Ok great. Good advice. I will start with the intercooler and pipes. And see what changes and update. Hopefully this weekend. Thanks guys.

[knobby1]

Ok great. Good advice. I will start with the intercooler and pipes. And see what changes and update. Hopefully this weekend. Thanks guys.

You have a 2008 2.4 Euro-4...you don't have a DPF....intercooler pipe is getting sucked in due to blockage upstream of the inlet manifold....either the turbo is munted or airway blocked between air filter and inlet manifold....I'd suspect the intercooler is blocked, possibly with old air filter bits or the turbo is indeed munted.

Lord Knobrot (Smithy)

[DanMK7uk]

Have you yet checked the turbo and or intercooler is clear?

[Bat135]

*** UPDATE. PROBLEM SOLVED ***

I took off intercooler. It was filled with black sludge. Mainly charge pipe sucked in side.

I didn’t need to take any front numbers iff or anything. Intercooler came off with four torx head bolts.

Cleaned it with petrol and then water. Blocked both ends and shook with petrol inside. Rinsed and repeated several times.

Then with water ect. Dried with compressed air and my leaf blower that fit exactly over the intercooler outlet/inlet.

Turbo fine. Checked it and checked air coming out of pipe when intercooler removed.

Lots of gunk in inlet too. Cleaned this very carefully.

Suspected from previous turbo failure as replaced this couple of years ago with reconditioned unit but didn’t know to clean pipes or intercooler.

So guess it just built up from then eventually clogging pipe. And the EGR tgat I replaced could have contributed or been damaged too as a result. Not sure which.

No error codes. Injector pilot learn done.

In my rush and haste on Friday I put 20 quid of unleaded in it by mistake. Started it Saturday am and loads of smoke. Realised what I had done and got 14 Jerry cans of diesel into it. My mate took me with several trips and few Jerry cans. Luckily I diluted it in time. But it might have done it some good in a strange way. Anyways. After that and the intercooler clean it running like new sgain. Not a tiny bit of smoke. Nothing.

Thanks to all for advice and opinions. It did help. Hopefully it helps others.

[DanMK7uk]

*** UPDATE. PROBLEM SOLVED ***

I took off intercooler. It was filled with black sludge. Mainly charge pipe sucked in side.

I didn’t need to take any front numbers iff or anything. Intercooler came off with four torx head bolts.

Cleaned it with petrol and then water. Blocked both ends and shook with petrol inside. Rinsed and repeated several times.

Then with water ect. Dried with compressed air and my leaf blower that fit exactly over the intercooler outlet/inlet.

Turbo fine. Checked it and checked air coming out of pipe when intercooler removed.

Lots of gunk in inlet too. Cleaned this very carefully.

Suspected from previous turbo failure as replaced this couple of years ago with reconditioned unit but didn’t know to clean pipes or intercooler.

So guess it just built up from then eventually clogging pipe. And the EGR tgat I replaced could have contributed or been damaged too as a result. Not sure which.

No error codes. Injector pilot learn done.

In my rush and haste on Friday I put 20 quid of unleaded in it by mistake. Started it Saturday am and loads of smoke. Realised what I had done and got 14 Jerry cans of diesel into it. My mate took me with several trips and few Jerry cans. Luckily I diluted it in time. But it might have done it some good in a strange way. Anyways. After that and the intercooler clean it running like new sgain. Not a tiny bit of smoke. Nothing.

Thanks to all for advice and opinions. It did help. Hopefully it helps others.

Excellent well done mate