Hi all

 

Posting this because it took me ages to figure this out (we're talking a good 18 months). I'm hoping this will be useful to someone.

 

Symptoms:

I started to notice a slight whistle from the engine when coming on boost in (in 4th mainly).

About 6 months later, the whistle went... but the car developed a hesitation on boost (again, most noticeable in 4th)

6 months after that, the hesitation went and I started to notice black smoke on boost in all gears but mainly 3rd upwards (as I would be on throttle longer i guess). There was also a slight loss in power.

What I tried to fix this:

--Changed the MAF

--Cleaned and subsequently blocked off the EGR

--Oil, filter changes

Then... about a week ago (18 months in)... I noticed oil on the radiator fan, starter motor and under the sump... but couldn't find the source.

I also noticed the leak wasn't dripping... kinda like it was a gradual or intermittent leak. That got me thinking... I opened the bonnet, started the engine and asked my other half to rev the engine. I was feeling around the inlet manifold and noticed air rushing out the underneath of the inlet pipe between the inlet manifold and the intercooler!!!

Strange thing was I felt underneath there months ago... but couldn't feel a crack... I needed the pressure build up to make it obviouse!

Picture attached for reference.

Pipe replaced... all working fine.

I hope this helps someone in the future :). (By the way... yes... I have noticed many related posts now that I've fixed the problem. I just couldn't feel the crack in the pipe when the engine was off, so didn't thing there was a crack in the pipe.)

Happy motoring 🙂

nice post.  i have the 2.0 duratorq engine also.  but have not had same issues.   but gud to know for the future.   thankyou

On 9/10/2020 at 9:12 PM, GTDriver said:

Hi all

 

Posting this because it took me ages to figure this out (we're talking a good 18 months). I'm hoping this will be useful to someone.

 

Symptoms:

I started to notice a slight whistle from the engine when coming on boost in (in 4th mainly).

About 6 months later, the whistle went... but the car developed a hesitation on boost (again, most noticeable in 4th)

6 months after that, the hesitation went and I started to notice black smoke on boost in all gears but mainly 3rd upwards (as I would be on throttle longer i guess). There was also a slight loss in power.

What I tried to fix this:

--Changed the MAF

--Cleaned and subsequently blocked off the EGR

--Oil, filter changes

Then... about a week ago (18 months in)... I noticed oil on the radiator fan, starter motor and under the sump... but couldn't find the source.

I also noticed the leak wasn't dripping... kinda like it was a gradual or intermittent leak. That got me thinking... I opened the bonnet, started the engine and asked my other half to rev the engine. I was feeling around the inlet manifold and noticed air rushing out the underneath of the inlet pipe between the inlet manifold and the intercooler!!!

Strange thing was I felt underneath there months ago... but couldn't feel a crack... I needed the pressure build up to make it obviouse!

Picture attached for reference.

Pipe replaced... all working fine.

I hope this helps someone in the future :). (By the way... yes... I have noticed many related posts now that I've fixed the problem. I just couldn't feel the crack in the pipe when the engine was off, so didn't thing there was a crack in the pipe.)

Happy motoring 🙂

I have a different engine (1.8 TDCi) but there's a little 90 degree rubber hose that's prone to cracking on it's underside (where you can't see it) and I also only found when I got someone to aggressively rev out the engine to build up a bit of boost whilst I felt around the hoses.  I also made sure the engine was nice and warm to ensure that any air leak would be nice and warm, and easy to feel.

 

It's surprising how often the simple/basic tests correctly identify the root cause of an issue.

exactly same problem on

2009 tdci 2Ltr  / 90k +milage 

noticed alot of black smoke - loss of power etc 

paid for diagnostics / smoke tests  etc  ( 1 garage said i needed new turbo @ £700 !!! ) 

had a play myself by taking of top part of hose (inlet manifold and the intercooler   by loosening jubilee clip ) only to find a 4 inch split on underside ( hidden from view )

ordered after market pipe from ebay @ £20 as its only a rubber tube ( normally only fit ford parts ) 

whilst waiting for part ... used some gorilla glue non drip in crack & strong gaffer tape as a temp fix - tbh worked really well and proved this was the Root of the problem !!

i did the below to fix mine .....

part came , took  out drivers headlamp &   light cable to access bottom jubliee clip , ( 1 screw and gently guide clip down as not to snap )  buy / or use a stubby short screw driver to undo / retighten - put bottom hose in boiling water to soften [ dry when fitting ] as helps not to force new tube on plastic without causing damage  )  , transfer the old clips onto new ( they have lugs on to grip tube - inside - they tighten as you tighten clip - avoid Over tightening as its rubber to plastics 

slide headlight back in gently  ( line up clip ) - not forgetting put head lamp cable back on 

 

bottom hose bit fiddly as no much room and i have no rams etc 

when done  gently start / rev to see all is secure - do at your own risk , but my car runs amazing now - no smoke and loads of boost 

approx time to fix - 30mins as no expert

garage prob take 5 mins 

https://fordowner.b-cdn.net/uploads/monthly_2020_09/1897644960_IMG_21866088.JPG.c24f414c4cfd58c1237c1de3aeb6a474.JPG