Diesel intercooler query

[75driver]

The intercooler gunk is on the drivers side. It is a bit oily, but not fresh....like it’s been there for some time.
I did try to spray on some solvent and wipe with a rag, but it only really smeared the gunk.
I think the only reasonable course of action is a bumper off job and
A) try more solvent spray
B) powerhose..😞


Sent from my iPhone using Tapatalk

[75driver]

Originally Posted by marinabrian

Ooh missing stiffnut and for some time too, how did I miss that



Perhaps a visit to specsavers is in order



Anyway, I blame whoever installed the exhaust, as that's been missing for some time by the look of things Sean.



Buy one of THESE and remake the joint.



Was there any hint of black soot around the flange? if so this may be the culprit of the mystery smell



The intercooler, which end was being photographed ?



Brian

Hi Brian, no, there was no black soot that I could see, but I will still probably buy and fit the gasket you linked to.👍
Something tells me that if the flanged joint was installed with only 2 of the 3 nuts, installing the 3rd nut now (which I’ve done) may not even make much improvement on sealing the gasket (that I only suspect may be leaking).
Hence I’ll remake the joint again as suggested.


Sent from my iPhone using Tapatalk

[T16]

Surely if you powerwash a 15year old intercooler, you will just wreck or completely remove all the little fins that become brittle over time....

[75driver]

Originally Posted by T16

Surely if you powerwash a 15year old intercooler, you will just wreck or completely remove all the little fins that become brittle over time....

Yes, that is a strong possibility.
I was thinking of trying gunk remover first, and then going gently with the power washer.



Sent from my iPhone using Tapatalk

[clf]

Originally Posted by 75driver

Yes, that is a strong possibility.
I was thinking of trying gunk remover first, and then going gently with the power washer.



Sent from my iPhone using Tapatalk

If you have concerns perhaps an airline or the 'jet' setting on a common garden hose head .

Sent from my SM-A600FN using Tapatalk

[75driver]

Well, I had another look at the intercooler today, and found the offending hole(s).
1 of them is actually visible in the second post of the thread.😳
Difficult to photo the 2 holes but at least 1 is visible behind where the FBH temperature sensor wiring was previously located. (thought to be the cause).


So folks, what’s the options:
- worth fitting a 2nd hand unit?
- new? Have seen a post about a GM unit so might opt for that.


Sent from my iPhone using Tapatalk

[alanaslan]

Originally Posted by 75driver

Had a wee rummage under the duo tone today, and noticed the leak intercooler didn’t look too smart on the drivers side.
Photo from below:

And from the front, through the grille...

Just wondering if the crud is likely to be due to a hole in the intercooler, or due to the fact that no undertray fitted?
Also spotted a lack of a securing nut on the exhaust flange...



Sent from my iPhone using Tapatalk

Your intercooler is fine in the respect of it leaking. But it is not cooling anything needs the muck cleaned out the radiator. Pressure washer on low pressure even a garden hose get that field out of it. Once you have done that she will feel like a different car.
As to the manifold nut just run a new one up it, whilst praying that some nice exhaust fitter hasn’t run the last nut up it with a power gun totally stripping the thread off it.
Alan


Sent from my iPad using Tapatalk

[75driver]

Originally Posted by alanaslan

Your intercooler is fine in the respect of it leaking. But it is not cooling anything needs the muck cleaned out the radiator. Pressure washer on low pressure even a garden hose get that field out of it. Once you have done that she will feel like a different car.
As to the manifold nut just run a new one up it, whilst praying that some nice exhaust fitter hasn’t run the last nut up it with a power gun totally stripping the thread off it.
Alan
Sent from my iPad using Tapatalk

Afraid not Alan. 😞.
When I put my finger over the holes shown in the photo, I can feel the air pressure leaking out.☹️
The oily gunk is only in a 6” area around the holes. The rest of the intercooler is clean.
I hope this may be the cause of the deisely exhaust smells I’ve been getting.
Well, at least I hope that fixing the intercooler sorts that problem out as well.🙄
New nut has been successfully installed on the exhaust downpipe flange.😄
No leaks visible from this joint.




Sent from my iPhone using Tapatalk

[trikey]

Originally Posted by T16

Surely if you powerwash a 15year old intercooler, you will just wreck or completely remove all the little fins that become brittle over time....

The ones ive done have been fine, the secret is to powerwash them from the front, and blasting water at the fins sideways can break them.

[alanaslan]

Originally Posted by 75driver

Well, I had another look at the intercooler today, and found the offending hole(s).
1 of them is actually visible in the second post of the thread.😳
Difficult to photo the 2 holes but at least 1 is visible behind where the FBH temperature sensor wiring was previously located. (thought to be the cause).


So folks, what’s the options:
- worth fitting a 2nd hand unit?
- new? Have seen a post about a GM unit so might opt for that.


Sent from my iPhone using Tapatalk

If you are sure it is holed then replace it with a second hand unit.
In the past I have seen me removing the cooler rad and washing it outside and in in the solvent bath with the pump on medium, boy thee look different cleaned up.
If the tanks had a hole in them then it was a a rub with steel wool a coating of flux and silver solder up the offending hole. I used even to be happy silver soldering up individual vertical galleries.
Sadly these days are past can’t hold a micro torch steady enough and also need a very big magnifying glass to see the thing.
Many units are made from thermoplastic these days though don’t remember seeing a plastic one on a 75 but the same repair holds good for them. Just the micro torch gets changed for a plastic welding gun.
Find an afternoon and take it out and give it a good clean so you can see what you are dealing with.
I have fond memories of the winter of 79 I was on station at RAF Swinderby ne’er Newark it was February and there was three feet plus of snow. Then we used to fit ploughs to the front of 7.5 Tonners the only problem was if the driver clipped the kerb with the plough at speed he sent the full plough rig through the main Coolant Rad. We had one tractor with front bucket, along with eight plough units for 7.5 tonners. I seem to remember spending that month repairing Rads at the rate of about five a day.
Personally I think it was a race to see if I could keep the wagons on the road, before the drivers wrecked them. We had to get antifreeze airlifted in by rotary wing aircraft 6, 45 gallon drums to supplement out 3, 45 gallon drums.
Just for fun before falling into my rack one night I welded up a plough with adaption brackets to fit the front of a Jaguar V12 powered, tracked personal carrier. It’s Rads we’re mounted on the flat at the rear of the unit. My joke and the tractor were the only two that I did not have in for repair many many times.
It is sad to think that Airfield is no longer there, think the blew a large part of it up for an episode of “London’s Burning” where the story line had a LPG gas bottling plant on fire.
Sorry for the bit of life story but just had to get it out. Old age !!!
Ba Humbug.
Alan


Sent from my iPad using Tapatalk