Changing the oil in a car turbine drives oil into the intercooler

Rules for flushing the intercooler

When cleaning the heat exchanger, do not use devices with pressurized water supply. The pressure can damage the aluminum plates. The type of detergent does not particularly affect the result. There are two ways to wash:

• external;
• internal.

The first method allows you to flush the intercooler without removing it; the second method requires dismantling. During the cleaning process, various cleaners for radiators and engines, gasoline, kerosene, and solvent are used. Almost any product that copes well with severe stains will do.

The removed cooler can be washed better, since most of the foreign particles accumulate on the back side. The choice of method depends on the car’s mileage, degree of contamination and conditions of use. If oil gets into the intercooler, it must be cleaned twice. First, all dirt and salt deposits are removed, and then the surface is washed from oil. Gasoline and kerosene work well with this substance.

The need to disassemble the front panel and bumper depends on the car model and the location of the heat exchanger. In some cases, only dismantling the arch protection will be required. By carrying out external cleaning, you can avoid disassembling the device, but washing it will be much worse. To remove external contaminants, you will need a hose with low water pressure, a cleaning agent and a soft brush.

To remove the air intercooler, the clamps are loosened and the fasteners are disconnected. Water devices require the dismantling of all pipes. If there is a lot of dirt on the device, it is necessary to carry out mechanical cleaning. All kinds of growths, stones, and insects are removed. Curved plates are straightened using improvised means. Chemical means are used to remove deposits and dirt; you can use Profoam 2000. Internal parts are washed with acetone, white spirit, kerosene or engine and carburetor cleaners.

Cleaning the intercooler is a simple process that, together with drying, takes the driver 2-3 hours. Timely replacement of pipes will avoid breakdowns and costly engine repairs.

Precautionary measures

In the process of internally cleaning the device from oil, you have to work with aggressive flammable liquids, and also take precautions so as not to damage the intercooler itself:

1. During mechanical cleaning, do not use hard brushes, knives or other devices that can scratch or bend thin soft metal parts.
2. You should work with gloves and avoid contact of aggressive substances with your body.
3. Follow safety rules when working with flammable materials.

Purpose and features

Changing the oil in a car, which oil is thicker than 5w30 or 10w 40
Intercooler is a heat exchanger that cools the hot air coming from the turbocharger. The temperature can reach +200 °C, which is due to the heating of the compressor and the compression of air flows. There are two types of intercooler cooling:

• air;
• aquatic

In the first case, the radiator releases excess heat into the atmosphere. The simple design has made this type the most popular among car manufacturers. The second type involves cooling with water. The unit has a compact size and high operating efficiency. Its structure is more complex and includes an additional liquid cooler, a transfer pump, and a control system.

Externally, the intercooler is a radiator with many strokes, plates and tubes that dissipate heat. The long length of the nozzles and their absence of bends make it possible to maintain high pressure in the structure.

The operating efficiency of the device is very high. The engine increases its power by 3% when the temperature drops by 10°. Air intercoolers cool the exhaust streams by 50° and accelerate the engine by up to 15%. For water systems, the reduction reaches 70° and the engine efficiency increases by 21%. The intercooler also has a number of disadvantages:

• During friction inside the structure, the working fluid loses some energy, which reduces air pressure;
• the device adds up to 20 kg to the total weight;
• High-quality operation of water devices is impossible without cooling fluid, the leakage of which significantly reduces the efficiency of operation.

Intercooler: purpose and advantages

Intercooler in a car
No matter how strange it may be, not all owners of modern cars with a turbocharged engine are sufficiently knowledgeable and understand the instruments and parts found under the hood of their car. There is no need to talk about the presence of an intercooler there. That is why in the article, it is first worthwhile to understand what kind of device it is and what it is eaten with.

An intercooler, or as it is literally translated from English - an intercooler, is a radiator or heat exchanger, the main purpose of which is to cool the superheated air coming from the turbocharger. The temperature of this same air, as a rule, reaches 200 ˚С. This overheating is facilitated by the temperature of the compressor itself and the thermodynamic effect of air compression. From a school physics course, many people remember that heating the air promises a decrease in its density, and in the case of turbocharging, because of this, its pressure will also significantly decrease.

According to experts, the intercooler is capable of reducing the air temperature to 50 °C, which will ensure significantly better filling of the engine cylinders, and accordingly increase its power, increase efficiency and reduce the level of harmful emissions. It is not at all strange that the use of an intercooler, if all systems are in good working order, guarantees an increase in engine power by 20%!

Interestingly, by cooling the air, the intercooler creates an obstacle for it, and this also affects the boost pressure. But despite this, the device provides significantly more advantages, which is why its use can be called a compromise to achieve the desired effect.

What is an intercooler for?

Changing the oil in a car: is it possible to add oil to a hot engine?

The cooler is a kind of radiator. The purpose of the device is to cool the compressed air before supplying it to the cylinders of the internal combustion engine. Cooling allows more air to be placed into the cylinder, resulting in more fuel being burned. The engine power when supplying cold air under pressure is much higher. The location for installing the intercooler is naturally the area after the turbine. The use of a cooler on a diesel engine made it possible to achieve an increase in power, reduce the toxicity of exhaust gases, obtain complete combustion of the fuel-air mixture, and reduce fuel consumption. The turbocharged diesel engine has become more revving, the low-end torque characteristics and engine efficiency have increased, and the maximum speed of diesel engines has become higher.

The installation of an intercooler on a diesel engine is due to the fact that engines of this type are extremely demanding on the temperature of the working mixture compared to gasoline internal combustion engines. The cooler is capable of reducing the charge air temperature to 55-70 degrees Celsius.

Air cooling in the system can occur according to the following schemes:

• air cooling;
• liquid cooling;
• combined scheme;

1. In the first case, air is pumped by a turbocharger and then passes through the intercooler honeycombs, releasing excess heat into the atmosphere. This diagram resembles the operation of a radiator in an engine cooling system.
2. Cooling according to the second scheme involves passing air through a device filled with cooling liquid. Such a solution is structurally more complex and more expensive, since it requires the installation of an additional pump for pumping liquid, as well as separate electronic control units.
3. Combined cooling is used in turbocharging designs on high-performance racing cars. The charge air cooling circuit in such machines includes several intercoolers, some of which operate on the principle of air cooling, while others are variants of liquid radiators. Coolers in combined circuits are used in series.

Cooling based on the air-to-air principle is less efficient compared to air-to-water circuits and combined solutions. At the same time, the main advantage of an air radiator is the simplicity and availability of this solution, which led to the widespread installation of intercoolers of this type on serial diesel and gasoline cars.

What is an intercooler

Changing the oil in the Haldex coupling on a Tiguan

As is known, forced air charging under pressure allows you to burn more fuel and achieve a significant increase in internal combustion engine power without increasing the physical volume of the cylinders. This solution is widely used on almost all modern diesel engines, and is also used in the design of forced gasoline units.

The intercooler is a component element that is included in the overall turbocharging scheme. The fact is that the air is strongly compressed by a turbocharger, as a result of which it heats up. If heated air is immediately supplied to the cylinders, then its volume will not be enough for efficient and complete combustion of a portion of the fuel. Engine power decreases, fuel consumption also increases noticeably.

How to clean the intercooler from oil

In some cases, an oil leak, for example from a pipeline connecting the turbine and the crankcase, leads to the need to clean the intercooler. This is due to the fact that the turbine throws the oil flowing out of the hole into the intercooler.

Before flushing the intercooler of oil, you need to figure out how to remove the intercooler. Most air-cooled intercoolers can be removed within a few minutes; to do this, you need to loosen the clamps and remove the fasteners. The liquid-cooled intercooler is somewhat more difficult to remove, for which all pipes are unscrewed. In addition, you need to decide how to flush the intercooler of oil. It is necessary to flush the system with a detergent recommended in the instructions, but if such a liquid is not at hand or is difficult to find, then a universal chemical may be suitable: kerosene or white spirit.

When using these liquids, precautions should be taken to avoid contact with exposed areas of the body. Do not use hard objects for cleaning, such as a knife, brush or other tool that could damage the surface being cleaned.

After thoroughly cleaning the intercooler pipe from oil, you need to get rid of any remaining cleaning fluid. To do this, the part is washed with water, but not under pressure, so as not to damage the internal structure of the radiator. The water should be at room temperature; flushing should be carried out until clean liquid comes out of the intercooler.

Thus, it is not a problem to find a way to flush the intercooler; it is much worse to postpone repairs until later. It should be borne in mind that inexpensive replacement of pipes can save money on major engine repairs. If you cannot independently diagnose the reasons for the appearance of oil in the intercooler, contact a professional service center.

How to flush the intercooler after oil gets in

Once the cause of oil leaking into the intercooler has been determined and eliminated, it is also necessary to clean the intercooler itself before continuing to operate the vehicle. If the oil is not removed, it will enter the air flowing through the radiator. Thus, oil particles will end up in the air-fuel mixture, which will generally affect the quality of engine operation. At the same time, the quality of intercooler cooling of the passing air will decrease.

Please note: In rare cases, remaining oil in the intercooler may catch fire at high temperatures. To clean the intercooler from accumulated oil, you need to remove it from the car.

If a liquid intercooler is used, it is better to contact specialists or the removal instructions for a specific model. When it comes to an air device, it can be removed very simply - just loosen the clamps and unscrew a few bolts

To clean the intercooler from accumulated oil, you need to remove it from the car. If a liquid intercooler is used, it is better to contact specialists or the removal instructions for a specific model. When it comes to an air device, it can be removed very simply - just loosen the clamps and unscrew a few bolts.

Next, you should clean the intercooler. To do this, you can use specialized tools (information about which should be indicated in the vehicle’s operating instructions), or it is permissible to use universal automotive tools, for example, Profoam 2000.

Important: If the car’s operating instructions do not indicate that the intercooler can be cleaned with gasoline, as well as various solvents (white spirit), they cannot be used. Most likely, the use of such products will lead to irreversible damage to the device.

Once the intercooler has been cleared of any remaining oil, clean it of any remaining cleaner with distilled water.

Please note: Water must not be supplied under high pressure, otherwise it will damage the intercooler cells. Next, dry the intercooler (you can leave it to dry for several hours, or blow it with a hairdryer)

When blowing with a hairdryer, set the minimum temperature and minimum pressure to avoid damaging the device.

Next, dry the intercooler (you can leave it to dry for several hours, or blow it with a hairdryer). When blowing with a hairdryer, set the temperature and pressure to the lowest setting to avoid damaging the device.

When the intercooler is dry, install it back on the car.

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The main reasons for oil getting into the intercooler

As automotive practice shows, if there is oil in the intercooler of a diesel engine, the reasons for its appearance are very typical. They concern:

• various types of oil or air filter malfunctions;
• engine overheating;
• leaks in the turbine (which is often caused by damaged seals);
• damage to the ventilation system serving crankcase gases, etc.

Malfunctions of the crankcase ventilation system

Another common cause of oil penetration into the intercooler, experts call breakdowns in the crankcase ventilation system. Such a system should reduce the release of hazardous substances into the atmosphere from the crankcase. If normal ventilation of gases is not ensured (for example, due to a broken valve), the engine oil deteriorates its performance parameters, destroys the metal part of the engine, etc. The result will be the fixation of undesirable environmental and other problems, including oil leakage into the intercooler.

Oil filter clogged

Another typical reason for the unwanted presence of oil in a car’s intercooler is that the oil filter is clogged and does not fully perform its functions. Then a rarefaction zone certainly appears, due to which the sucked oil enters the intercooler. If this happens, you cannot do without thorough cleaning of the filter.

Dirty air filter

Sometimes the real cause may be a thoroughly clogged air filter. Its contamination does not allow it to pass, as expected, a sufficient volume of air. In this case, as in the previous case, a rarefied zone appears, creating a kind of “pump” that sucks in the oil. Here, too, you will have to resort to thorough cleaning of the filter in order to prevent the subsequent inevitable destruction of the seal rings.

Motor overheating

Oil on the intercooler pipe may also be the result of engine overheating. Many car owners abuse this, constantly forcing the engine to wear out without any good reason.

Sooner or later, such disdainful “attention” to the car on the part of the driver can lead to the appearance of unwanted and harmful malfunctions for the car, up to the failure of its important components

The turbine is leaking due to a damaged oil seal

Automotive professionals know that often the reason is that the turbine throws oil into the intercooler. Finding out the reasons why oil is rushing into the intercooler shows that this is due to a faulty oil seal through which the oil oozes.

Turbine return oil line bend

Sometimes the cause is such a “trifle” as a bent oil drain pipe installed between the engine crankcase and the turbine. If it is not straight, as it should be, but has significant bends, this could be the whole problem - due to the occurrence of increased turbine pressure. It increases so much that it forces the oil through the O-rings. Here, to normalize the situation, it is enough to give the oil pipeline an even shape.

Oil in the intercooler - what to do

Having found oil outside or inside the intercooler, it is necessary to determine why it got there. To do this, do the following:

• check the operation of the crankcase ventilation system;
• change oil and air filters;
• check the condition of the oil lines;
• check the turbine seals.

If you do not know how to carry out such diagnostics, visit a proven and reliable car service center. If the test results show that the engine is fully functional, reconsider your driving style. Rapid movement on a steep climb or mountainous terrain, long driving at engine speeds of more than 2 thousand per minute leads to an increase in coolant temperature.

Only after this is it necessary to start flushing the intercooler. You can flush the intercooler like this:

• remove the intercooler from the engine (read the repair and maintenance instructions for your car, it says how to do this);
• clean the outer surface of dirt with a broom and a stream of water;
• pour a mixture of gasoline, kerosene and acetone inside (ratio 1:1:1) and leave overnight;
• in the morning, drain the resulting slurry;
• mix hot water and dishwashing detergent (ratio 1:100), then pour this solution into the intercooler;
• To make washing more effective, shake it vigorously for 2-3 minutes;
• drain the dirty water and repeat the same washing two more times;
• drain the flushing solution and rinse the intercooler with clean hot water.

Sometimes flushing is done with diesel fuel, acetone, carburetor cleaner or other light petroleum products. Some craftsmen, in order to simplify the maintenance of the intercooler, drill the lower part of the device body and weld a nut to it, into which a bolt with a copper washer is screwed. Every 3 months they remove the bolt and drain the oil. Thanks to this, they not only avoid carburetion, but also determine the approximate condition of the engine and turbine. When the car's engine is fully operational, if oil appears in the intercooler, it is in insignificant quantities.

Conclusion

Now you know why oil appears in the intercooler and what to do if this happens. This will allow you to detect a motor malfunction in time, quickly eliminate it and prevent deterioration in engine performance. In addition, you learned how to properly flush the intercooler. The video below will help you not only theoretically imagine the phenomena described in the article, but also see them live.

Is it dangerous for oil to get into the intercooler?

First of all, you should become familiar with what the intercooler is designed for. This term should be familiar to those who operate a diesel engine. In addition to turbocharging, such engines have an intercooler. It was this that was dubbed the intercooler.

Figuratively speaking, this is a kind of radiator for cooling the fuel mixture

Since, structurally, it has clear functional tasks, oil in the intercooler is definitely an abnormal phenomenon, so it is important to determine how dangerous it is for the machine’s mechanism. There is no need to look for a definite answer here.

It all depends on several factors, each of which plays an important role.

Sometimes a slight presence of oil may not pose a serious threat to the engine. But this is only temporary, since it should not be there, and it will certainly negatively affect the functioning of the engine. So, after mixing the oil with the air flowing through the radiator, such an “enriched composition” will enter the fuel mixture and worsen its combustion efficiency. The most unpleasant option may be the oil catching fire, which often happens in practice in cases where the engine is overheated after prolonged operation at maximum capacity.

causes and solutions to the problem

Hi all. Today on AutoPulsar another very pressing issue will be raised that interests many motorists, especially owners of cars with turbines. I will try to answer the question: “Why does the turbine drive oil into the intercooler?”, and also for what reason this happens.

The problem is typically typical for diesel cars and occurs quite often. For those who don't know, oil in the intercooler is not normal; a working intercooler should not interact with engine oil. When the turbine drives oil into the intercooler, certain problems are observed with the engine, this manifests itself in the form of a drop in power, as well as a decrease in the oil level, in other words, a situation where the engine eats oil. I’ll say right away that if you discover a problem, it is highly not recommended to operate a car with such a breakdown, in order to avoid even greater troubles.

Why does the turbine drive oil into the intercooler?

1. Deformation of the oil drain pipe. The oil line itself is a bent tube. It is located between the turbine and the crankcase; it delivers oil from the crankcase to the turbine. For that. To understand whether this is the case, it is necessary to evaluate the general condition of the oil drain pipe. If the oil line is damaged or deformed, the delivery of the required amount of oil to the turbine occurs intermittently, and due to the deformation, the pressure in the system increases. Excessive pressure in the system causes the oil to look for any way to escape. As a result, leaking through the most vulnerable places, such as seals, it penetrates the intercooler.
2. Oil line is dirty. This problem usually occurs in cars with high mileage. High output and a number of related problems, including bad oil, lead to the turbine driving oil into the intercooler due to a clogged oil line. The internal diameter of the oil-conducting channel is reduced due to various deposits, as a result, the throughput is reduced. Excess pressure arises and, as I already said, the oil looks for a way out to reduce the pressure. Thus, it often ends up in the intercooler.
3. Faulty air duct. If the air duct is somehow damaged during operation, the turbine may begin to throw oil into the intercooler. The reason is that if the seal is broken, a vacuum zone appears, which draws in engine oil, throwing it into the intercooler. Minor punctures and cracks, in principle, can be repaired, but in case of critical damage, replacement of air ducts is mandatory.
4. The air filter is critically dirty. For owners of turbo engines, the cleanliness of the filter elements is very important, so replacement should be regular and, if possible, premature. Despite its simplicity, the air filter is a rather important element on which a lot depends, including the proper operation of the turbocharger. Lack of air with a dirty filter has an extremely negative effect on turbine performance. A vacuum zone appears in which oil is sucked in and thrown into the intercooler.

Relevant: What is a diesel turbo timer and is it worth installing?

What to do if the turbine drives oil into the intercooler and how to fix it?

The search for causes is described above; it is necessary to establish which one of them led to the fact that oil is thrown into the intercooler. After this, the cause is eliminated and the consequences of this phenomenon are eliminated. Basically, the problem comes down to the fact that a large amount of oil and carbon deposits cover the air channels, impairing the efficiency of the intercooler. This may result in the air flow not receiving proper cooling, causing it to overheat.

Cleaning the intercooler is carried out by mandatory dismantling of contaminated components. Without dismantling, cleaning the intercooler will be incomplete and superficial. Various chemicals that can dissolve oily deposits are used as a detergent, or it would be more correct to say a cleanser.

Timely detection of faults!

In this situation, the most important thing is to diagnose the problem in time. The sooner you notice that the turbine is throwing oil into the intercooler, the cheaper and easier the repair will be. Delay or a careless attitude can lead to turbine malfunction, the price of which is quite high. In addition, other components that interact with the turbocharger may fail along the chain.

The turbine drives oil into the intercooler, what is the reason and what to do?

Progress is moving forward, and this applies not only to electronic equipment, but also to car engines. Relatively recently, a motor with a turbine was installed on vehicles, but now it is found all the time. However, problems periodically arise with this unit when the turbine drives oil into the intercooler.

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Over time, parts become more and more complex, which affects the increase in the cost of their repair and the complexity of restoration. More and more new parts are being added to the engine compartment; for example, it is now difficult to imagine a turbocharged engine without an intercooler.

Many car enthusiasts, when inspecting the engine, were struck by the presence of traces of oil in this part, but this does not always mean any serious consequences or costs. This depends both on the frequency of car maintenance and on its mileage and the quality of the technical fluids and consumables used. In any case, you shouldn’t panic; you first need to figure out what an intercooler is and why the turbine needs it.

What is an intercooler for?

First off, what does it look like? An intercooler is essentially the same cooling radiator, only with larger diameter channels. And if water or antifreeze circulates in a car cooling radiator, then air passes through the intercooler, although also under pressure. They are divided mainly into two types, differing in their location:

• front ones are usually installed at the bottom of the car's front bumper. Often, to install it you have to install special bumpers or modify the standard ones. A more sporty option;
• horizontal. Basically, they are standardly installed on cars. They are usually placed on top of the intake manifold and as close to the hood as possible.

In order to understand why an intercooler is needed, you need to know the purpose of the turbine itself. And it is needed in order to force air under pressure into the combustion chamber to enrich the fuel mixture, which increases engine power. But simply one turbine cannot be used here, and therefore a higher power fuel pump is installed.

Turbine operation diagram

And immediately a new problem appears in the form of incomplete combustion of fuel. Why is this happening? From the physics course it is clear that a burning substance has a lower density in relation to a cold one, and so does air. Passing through the turbine, it heats up to two hundred degrees, and only then enters the engine intake system. And since there is more fuel in it than usual, it turns out that the mixture is not enriched enough. This is where the intercooler comes in handy, because the air passing through it is cooled to a temperature of about 60 degrees, as a result of which more oxygen gets into the combustion chambers. Thanks to this, the fuel burns completely, which means that the power and dynamics of the engine increase and the amount of harmful emissions decreases. Intercoolers can be passive, they are cooled by the movement of air created when driving a car, or active, with a liquid cooling system. Active ones are mainly installed frontally; they are much smaller in size, but they require a separate control unit, and sometimes a pump. Previously, intercoolers were installed only on diesel engines, but now the geography of their use is quite wide and they are installed on almost all types of engines equipped with a turbine. On conventional engines, they will not have any benefit, except for a sportier appearance of the car.

Why is there oil in the intercooler?

Oil in the intercooler of a diesel engine, like a gasoline engine, can only appear in one way - the turbine throws oil into the intercooler, so you need to look first at it or next to it.

One of the simplest and quickest repairs is a breakdown of the oil return line between the turbine and the crankcase. It should be relatively straight and without sharp bends, since when the turbocharger pipe is bent, the oil in the intercooler pipe stagnates and high pressure can be created, which will force the oil through the O-rings, and then the air flow will drag it into the intercooler. The pipe is made of a fairly rigid material, but over time it can lose strength, so it is advisable to replace it rather than simply reshape it into a straighter shape.

If everything is normal with the oil line, then you need to check the air line from the filter to the turbine for cracks or holes. Due to its malfunction, a low pressure area is created in the supercharger, which will gradually destroy the rubber seals in the turbine and draw oil from under them. The same thing can happen if the air filter is clogged because it has not been changed for a long time. The solution here is quite simple - change or clean the filter and restore the tightness of the air duct.

But not everything is always so simple; sometimes there can be more serious problems. For example, a blockage could form in the oil drain line due to carbon deposits or debris getting into it. When repairing an engine, some mechanics use sealant, which then clogs the oil line. Everything is simple here - remove the pipe and wash it, unless, of course, the sealant only created a plug in it. But it may also be that the oil in the crankcase rises above the required level, as a result of which it has nowhere to go from the turbine and it simply throws it into the intercooler. And it’s lucky if more oil was simply poured into the engine than required, but if the crankcase ventilation does not work, then this is already a problem. The main reason here may be worn piston rings, which causes some of the exhaust gases to enter the crankcase and create excess pressure. This can only be cured by a major overhaul of the engine.

How to clean the intercooler from oil

Let’s say the breakdown is fixed, oil no longer flows where it shouldn’t, it seems you can breathe freely. But an equally important part of the repair lies ahead, called intercooler cleaning. After all, if it is not washed, the oil along with air will mix with the fuel, which will somewhat deteriorate its quality, and can also lead to the appearance of carbon deposits on the pistons and valves.

In addition, due to the oil film, the air will not be able to cool as effectively as before, which will negatively affect engine performance.

Most air-cooled intercoolers can be removed in a few minutes; you just need to loosen the clamps and unscrew the fastening bolts. You will have to tinker with liquid-cooled intercoolers by first unscrewing all the pipes. The main thing is to mark and not forget which is which. In addition, you need to know how to flush the intercooler of oil. To wash, you need to use the detergent specified in the instructions, but if you don’t have it on hand or you can’t find the recommended product, you can try universal chemistry. The following products may be suitable for cleaning:

• petrol,
• kerosene,
• White Spirit,
• diesel fuel,
• Profoam

These products should be used with caution, observing all safety measures, and it is advisable to prevent their contact with open skin.

You can go to a car repair shop for this, but they will charge you quite a lot of money for this easy work, although it is still not clear for what exactly. Under no circumstances should you use metal brushes, knives or other objects that can deform the radiator when cleaning.

After the oil in the intercooler pipe has been thoroughly washed with chemicals or fuel, you must definitely get rid of the detergent.

To do this, you need to rinse it with water, but in no case under high pressure, since you can easily destroy the honeycombs, which will negatively affect its operation. You need to rinse quite a large number of times, no less than six, until clean water comes out of the intercooler. It is better to use water for rinsing at room temperature.

After washing, the radiator should be dried; this can be done using a hair dryer, setting it to medium temperature. You can also use a heat gun, setting it to medium power and pointing it at the intercooler.

If you wish, you can wash it from the outside, and if the honeycombs are clogged, it is better to do this without fail. This can be done using a car wash or simply under water pressure.

After washing and drying the intercooler, it is advisable to check and rinse all the pipes going both from the turbine to the radiator and from the radiator to the intake manifold. During washing, it would be useful to pay attention to the condition of the pipes, and if they are already roughened or cracks appear in them, then they need to be replaced.

The most important thing is to detect a malfunction in time, so it’s never a bad idea to just look under the hood and visually inspect whether everything is in order.

After all, the longer you delay repairs, the more oil will accumulate in the intercooler and the more difficult it will be to flush it out. And in some cases, this can only be done with the help of expensive professional auto chemical products. In addition, oil entering the combustion chamber negatively affects the condition of the engine and, for example, a cheap problem in replacing a pipe can result in a major engine overhaul if this is not done in time. Therefore, if you find oil ingress, you need to immediately begin diagnostics, establishing why there is oil in the intercooler, otherwise it can be much more expensive. If you can’t do it yourself or have doubts, then it’s better to trust professional auto mechanics from a trusted technical center.

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Self-cleaning of a diesel engine intercooler

After eliminating the malfunctions that led to the release of oil into the cooler, it is necessary to clean the intercooler. This procedure is necessary to ensure that the air cools normally and that the remaining engine oil in the air cooler does not mix with the air supplied by the turbine.

The entry of a mixture of oil and air into the cylinders reduces the efficiency of the diesel engine, leads to severe carbon formation and coking, changes the combustion conditions of the fuel-air mixture, etc. In critical cases, it is even possible that the engine oil in the cylinders may catch fire and the diesel engine may overheat.

1. To clean the intercooler yourself, you will need to dismantle it. Cleaning engine oil involves the use of special cleaners, which are widely available on sale. Before use, be sure to collect information about whether the selected product can be used to clean the intercooler of a particular vehicle.
2. It is not recommended to flush the intercooler with gasoline or kerosene, various solvents and other aggressive compounds. Certain coolers may be composed of materials that are easily destroyed by aggressive cleaning agents. In such a situation, there is a risk of completely disabling the device.
3. As for air coolers, to remove them you need to unscrew the mounting bolts and remove the clamps. Removing the liquid cooler will require careful study of the instructions.
4. The cooler must be flushed in strict accordance with the manufacturer's instructions, which are indicated on the cleaner packaging. After washing, it is necessary to thoroughly rinse off any remaining chemicals using running water.
5. Many car enthusiasts use Karcher to clean the engine compartment. In the case of washing the cooler, you can also use this method. It should be noted that water must be supplied strictly under low pressure. The cooler honeycomb is quite fragile; water can damage the device if it is supplied intensively.
6. Flushing must be repeated until clean water begins to flow out of the radiator. When finished, it is necessary to dry the cooler thoroughly to eliminate the possibility of the presence of water. To speed up the drying process, the intercooler inside is carefully purged with compressed air with minimal pressure.
7. It is also necessary to thoroughly rinse the outside of the cooler to remove dust, dirt and engine oil residues. The final step is to reinstall the cleaned device.

• Periodic external cleaning of the intercooler honeycomb is a preventative measure and allows you to improve the efficiency of the turbocharging system.
• The appearance of even a small amount of engine oil in the cooler requires stopping the operation of the internal combustion engine until the cause is eliminated.
• Active use of a car with a obviously faulty turbocharging system can lead to more serious damage to the power unit.

How to properly clean the intercooler

In what cases is it necessary to clean the intercooler, and how to do it yourself? How does the state of this module affect the operation of the car engine? These questions are often of interest to owners of cars equipped with a turbocharging system.

The intercooler is an integral element of this system of forced air injection into the combustion chamber of the engine, and is a heat exchanger that cools this air. The performance of the car, as well as the safe operation of the vehicle, depend on its technical condition and correct operation.

Purpose of the intercooler

The purpose of equipping a car with a turbocharging system is to create additional air pressure in the engine cylinder, due to which the flammability of the mixture consisting of fuel and air increases. This helps to increase engine power while maintaining its dimensions and weight, save fuel and reduce emissions of harmful substances into the atmosphere.

However, when air is compressed, its temperature increases significantly, which entails undesirable consequences:

• hot air has a lower density, that is, the boost effect is reduced;
• in gasoline engines there is a risk of detonation;
• toxic compounds are released into the atmosphere.

In order to cool the air compressed by a turbocharger, an intermediate cooling device called an intercooler is included in this injection system:

1. The intercooler is an air or liquid radiator, and is installed between the compressor and the intake manifold.
2. Structurally, it can be located in the front part of the car behind the bumper or under the hood above the engine, and also in some models - in the side parts of the front wings.
3. The intercooler is designed to ensure maximum heat transfer. It consists of many tubes and plates, which allows the heat of heated air to be effectively removed into the atmosphere.

The material of this cooling device must have high thermal conductivity, so aluminum or copper is used to manufacture this module.

Why is cooler cleaning necessary?

During the operation of the car, any of its parts inevitably becomes dirty. Since the intercooler is located in the front of the car, while driving, dirt, insects, small stones, sand, etc. get into it.

Moreover, oil accumulates in it, which, mixed with sewage, clogs the structure, which negatively affects the efficiency of this unit:

• heat transfer is reduced, since the crust of contaminants does not conduct heat and acts as an insulating material;
• there is no cooling of the air entering the cylinders from the turbocharger;
• due to lack of cooling, engine productivity decreases.

In addition, in winter, salt gets into the gaps between the aluminum elements, which is sprinkled on the roads, which has a detrimental effect on the material from which the cooler is made. It literally eats away aluminum.

How and with what to clean the intercooler

As a rule, an attentive car owner will immediately notice that the “iron horse” has begun to behave differently. The reason for the decrease in power may just be due to accumulated pollution. How to clean the intercooler yourself and is it possible?

Many car owners clean this unit themselves, washing it only on the outside, or also clean its inside surface. In order to carry out internal cleaning, the intercooler must be dismantled by loosening the clamps and disconnecting the hoses. Then the mounting bolts are unscrewed and the device is removed. The complexity of this process depends on the specific car model and the location of the intercooler.

For external cleaning without removing the cooler, car owners use Profoam 2000 or another product that is safe for the device material and designed to remove dirt.

The intercooler should be flushed with a stream of water supplied from a hose with low pressure so as not to damage the thin aluminum elements.

However, it is worth remembering that such cleaning will not be complete and thorough.

Internal cleaning is much more effective.

After dismantling the cooler, cleaning is usually carried out in the following order:

1. Small stones, insects and other debris are removed from the gaps between the plates.
2. Damaged plates are corrected, growths are cleared off.
3. Water under low pressure with a special detergent (Profoam 2000 or another) washes away dirt.
4. Cleaning of oil inside is carried out using a special product recommended in the instructions.

If there is none, then car owners often use:
Flush the intercooler several times until the drained liquid remains clean. There should be gaps between the radiator fins. After cleaning, the intercooler should be dried thoroughly.

Precautionary measures

In the process of internally cleaning the device from oil, you have to work with aggressive flammable liquids, and also take precautions so as not to damage the intercooler itself:

1. During mechanical cleaning, do not use hard brushes, knives or other devices that can scratch or bend thin soft metal parts.
2. You should work with gloves and avoid contact of aggressive substances with your body.
3. Follow safety rules when working with flammable materials.

After internally flushing the intercooler of oil, it must be thoroughly rinsed and dried so that there are no residual flammable substances left inside.
If you have any doubts about cleaning this module yourself, you must contact the service center for specialist help. Neglecting intercooler maintenance can soon lead to a major engine overhaul.

Concept and principle of operation

Oil in the intercooler of a diesel engine, what is the reason? First, let's figure out what an intercooler is and what it comes with. The challenges now facing leading engineers are to maximize power by minimizing size, fuel consumption and emissions. This is not an easy goal. One option to increase power is to increase the pressure in the cylinders to ignite the fuel.

The latter consists of fuel and oxygen, which is delivered into the chamber under turbine pressure. Thanks to this chain, the ignition speed increases and the power increases. Anyway, the effect has been achieved. But far from it. Along with increasing power, the temperature inside the engine rapidly increases. As a rule, turbines are installed in diesel engines. So for the latter, elevated temperature is very harmful. In order to prevent premature failure, engineers developed an intercooler - a mechanism designed to cool the temperature of the compressed air in the engine. The principle of operation is quite simple. It resembles a motor cooling system by reducing the temperature due to cold air.

Intercoolers are structurally of two types:

• system :
  the simplest and most practical design. The operating scheme is as follows: air passes through the radiator honeycombs, similar to a standard one. In this way, the cooling process takes place and a cooled stream enters the chamber;
• Air-water:
  the hot flow after the turbine passes through a radiator with water, in this way cooling occurs. But this method is expensive in that it requires installation of, in addition to the radiator, a pump for pumping water and an electronic control unit.

Should be taken into account implanted into production machines

A diesel engine cannot compete with the same performance as a gasoline engine, so a supercharger has become the optimal solution. But there is no smoke without fire

. The main and most common problem with turbochargers is engine oil leaking into the supercharger system. The reason must be sought exclusively in the device that is lubricated with oil. A common practice is severe wear of the oil scraper rings, which allow vapor from the combustion chamber to pass into the crankcase pan. Solution to the issue: a major overhaul in the form of tossing the rings. The reason why oil is in the intercooler of a diesel engine has been clarified. A quick repair will get your car back on the road.

Troubleshooting methods

Naturally, the choice of one or another troubleshooting solution directly depends on what exactly caused the oil to drip or flow from the turbine. However, we list the most likely options, from simple to more complex.

Replacing (in extreme cases, not undesirable, cleaning) the air filter. Remember that it is advisable to change the filter a little earlier than the regulations, by approximately 10%. On average, it needs to be replaced at least every 8-10 thousand kilometers. Check the condition of the air filter cover and pipes; if a blockage is detected, be sure to thoroughly clean them, removing debris. Check the tightness of the air filter cover and pipes. If you find cracks or other damage, depending on the situation, you can try to repair them by applying clamps or other devices; in extreme cases, you need to buy new parts instead of the damaged ones. In this case, a prerequisite is that if depressurization has been detected, then before assembling the system with new components, it must be thoroughly cleaned of debris and dust that are in it. If this is not done, the debris will act as an abrasive and significantly wear out the turbine. Correct selection of engine oil and its timely replacement. This is true for all engines, and especially for those equipped with a turbocharger. It is better to use high-quality synthetic or semi-synthetic oils from well-known manufacturers such as Shell, Mobil, Liqui Moly, Castrol and others. It is periodically necessary to monitor the condition of the oil pipes so that they ensure normal pumping of oil through the oil system, in particular, to and from the turbine. If you completely change the turbine, then for preventive purposes you need to clean them, even if at first glance they are relatively clean. It won't be unnecessary! It is necessary to regularly check the condition of the shaft, impeller and bearings to prevent significant play. At the slightest suspicion of a malfunction, you need to perform diagnostics. It is better to do this in a car service center, where there is the appropriate equipment and tools. If there is oil at the outlet of the turbine, then it makes sense to check the condition of the drain tube and the presence of critical bends in it. In this case, the oil level in the crankcase must be higher than that of the hole in that tube. It also makes sense to check the crankcase ventilation

Please note that condensation that forms in the exhaust manifold due to temperature differences is often mistaken for oil, since the moisture mixes with dirt and turns black. You need to be careful and make sure that it is really oil. If there is a leak in the intake or exhaust system of the engine, then it also makes sense to check the condition of the gaskets

Over time and under the influence of high temperatures, it can wear out significantly and fail. Accordingly, it needs to be replaced with a new one. You should do this yourself only if you are confident in your knowledge and practical experience in performing such work. In some cases, instead of replacement, simply tightening the tightening bolts helps (but less often). However, you should also not overtighten, as this can lead to the opposite consequences when the gasket will not hold pressure at all.

Remember that overheating of the turbocharger contributes to the formation of coking from the engine oil on its surface. Therefore, before turning off the turbocharged engine, it is necessary to let it idle for a while so that it cools down a little.

It is also necessary to remember that operation at high loads (at high speeds) not only contributes to excessive wear of the turbocharger, but can also lead to deformation of the rotor shaft bearing, oil burning, and a general reduction in the life of its individual parts. Therefore, if possible, this mode of engine operation should be avoided.

About tightness

COMMENT! Guys, even a completely serviceable turbine will consume oil, this is normal in modern realities! Unfortunately, this is the design of such an engine, and the more you “heat” the trigger, the greater the consumption will be, these are a kind of dependent constants. Also, the oil consumption is approximately 1.5 - 2.5 liters per 10,000 kilometers; if you have more than “3”, then you need to check the unit.

So why does this happen? Just think and everything will fall into place. As I wrote above, two oil channels approach the bearings, one for the hot part, the other for the cold part, they are lubricated and this lubricant again goes into the engine. But how are the bearings sealed?

I want to say right away that the bearing should not come into contact with the impeller, which is spinning, otherwise the oil will directly flow into the intake manifold on one side and into the muffler on the other. Therefore, between the bearing and the impeller there are so-called “snap rings”. The pressure that is created by the impellers (and it is greater than atmospheric pressure) seems to “prop up” these rings, preventing the oil from escaping in large volumes; of course, it may ooze a little, but this is again within normal limits (this is a consumption of 1.5 liters per 10000 km).

I hope I explained it clearly, now we come to the malfunctions.

Why is oil leaking?

If something disrupts normal operation - suction (air release), oil supply, shaft rotation, bearing operation - the turbine begins to drive oil. And you know, you first need to figure out why this happens, otherwise after replacing the turbine with a new one, the oil will also leak out! THE REASON IS NOT ALWAYS IN THE UNIT ITSELF!

First, indirect reasons that you can eliminate yourself

After all, it is important to understand that often the “rush” of oil occurs due to a violation of pressure, that is, the locking rings do not cope with the task, the pressure from the impellers is disrupted, and the oil flows much “easier”. This indicates increased pressure at the turbine outlet, which needs to be removed

1) Check the air filter, it should be clean, in general I recommend changing the air filter 10% more often than expected. If it is clogged, replace or clean it

IT IS IMPORTANT!

2) If the filter itself is fine, look at the box and the intake pipe, it may be the problem with them. For example, there was fluff (from poplar trees).

3) We check the tightness of the filter housing (cover); if there is no tightness, then sand, dust, etc. will enter the turbine. is almost 100% guaranteed, and this in turn works as an “image” - it will kill the unit very quickly.

4) If you notice that the seal has been broken

It is IMPORTANT that you remove all the pipes and clean them - rinse them up to the turbine, and you also need to remove and rinse and clean them from the turbine to the intake manifold. The collector itself also needs to be cleaned, most likely there is dirt there - 100%

The air filter for the turbine is a very important component, because basically it drives oil only because the pressure is broken due to a clogged filter or pipes! Therefore, make a rule for yourself: change the filter every 8,000 km, and also check the condition of the housing for cracks, dirt, etc. Remember a clean filter, this already adds life to your unit.

The second most common reason is the oil itself - if it is of poor quality, or you change it rarely, a breakdown is “just around the corner.” Why does this happen?

1) The oil must be heat-resistant, it is specially sold for turbines, it should not burn, because while lubricating the bearings, it encounters high temperatures. If you fill it with regular oil, it will “coke” all the lubrication channels of the bearings, and they will simply fail. RESULT – we choose correctly!

2) Replacement interval. Even the best oil wears out and begins to lose its properties - to burn. Therefore, replacing it frequently will also protect you from “coking” of the oil passages. If your manufacturer specifies an interval of 10–12,000, then change it at least 10% more often, for example, at 9–10 thousand; believe me, the turbine’s life will increase.

3) Branch pipes. Often the cause is underwater oil pipes; if you have not changed the lubricant for a long time, they also become clogged

Even if you then change the turbine, the pipes must also be changed or cleaned, this is important!

If there is oil in the intercooler (in the intake manifold), the air filter (its adjacent structures) is most likely clogged, or the oil pipes are clogged. There is a difference in pressure.

If there is oil in the muffler - essentially the same problems, first of all, the oil pipes and the oil itself are “aired”! I would even remove the turbo and clean it and all the surrounding oil and air lines.

Of course, the above reasons are not a panacea; perhaps your unit itself has already worn out.

Needless to say, if you violate the operating rules, your turbine will fail very quickly.

1) The impeller is broken, indicating a large play on the shaft.

2) Oil flows more than normal, indicating bearing wear.

3) The shaft is jammed and the impeller does not rotate at all.

For all these reasons it changes. But these are already complex cases, some can only arise when it has really worn out, it’s just time.

In conclusion, to summarize, if the oil is leaking, this does not mean it has failed, we check the air filters and oil. pipes Now it’s a little bit for understanding.

I’ll end here, there will be more useful articles.

https://avto-blogger.ru

Why does the turbine drive oil into the intercooler?

Turbine mechanisms operate at high speeds and require good lubrication. Oil comes from the engine system, lubricates the turbine components and is then discharged into the crankcase. It is this oil that, under unfavorable circumstances, can get into the intercooler.

None of the car owners want to hear from the mechanic: The turbine has lost oil. This means that the device is becoming unusable and will soon need repair or replacement. It would seem that the turbine itself is to blame. But that's not true. Most likely, she was let down by the assistants through whom oil and air flow. The turbine is a very complex and capricious mechanism that operates at high speeds. In order for it to cope well with its duties, it needs clean oil and air, in sufficient quantities and under optimal pressure.

Therefore, the first thing you need to pay attention to is the oil line, air duct and air filter

Deformation of the oil drain line

Finding out this reason for oiling is easier than others. It is enough to inspect the oil line. It discharges lubricant into the engine crankcase. If the tube is pinched, deformed or incorrectly bent, then the oil through it does not drain well from the bearing assembly. It seeps through the seals into the turbine housing and is forced through the intercooler into the cylinders. In this case, simply replacing an inexpensive tube will save you from costly repairs.

Oil line contaminated

Oil from the turbine flows into the crankcase by gravity. Therefore, even simple contamination of the tube leads to difficulty in draining and an increase in pressure in the turbine components. The reasons may be:

• use of low quality oil
• untimely replacement
• bad sealant
• incorrectly installed gaskets

Under the influence of temperature, dirty and cheap oils form carbon deposits on the inner surface and clog the oil line. Poorly installed gaskets block inlet openings. The sealant can get into the tube under the influence of temperature. Therefore, you need to use the oil recommended by the car manufacturer and change it promptly. When installing oil pipelines, use thermal and oil-resistant sealants. Carefully and carefully install gaskets under the flanges. The contaminated oil line must be removed and washed.

Faulty air duct

An air duct is a regular rubber tube that can be punctured, torn, pinched or burned. Its malfunction will disrupt the operation of the turbine and cause oil to appear in the intercooler. Usually the duct is easily accessible and inspection is not difficult. Any damage is evidence in favor of purchasing a new one. It is inexpensive and easy to change.

Critically dirty air filter

The air entering the engine is contaminated with dust, abrasives, exhaust gases and other harmful particles. All the dirt accumulates on the air filter and it successfully copes with its duties until a certain time. A clogged atmospheric engine filter leads to loss of power and excessive fuel consumption. In turbo engines, these problems may be compounded by the appearance of oil in the intercooler.

A dirty filter impedes the flow of air and creates a vacuum at the turbine inlet. The seals are destroyed and oil enters the discharge chamber. The turbine begins to drive it through the cooler into the cylinders.

Turbocharged engines consume a lot of air, so the filter becomes clogged more often than usual and requires increased attention.

How and with what to clean the intercooler

Drivers who are interested in how to clean the intercooler on their own will inevitably have to dismantle it, otherwise thorough cleaning, even if they try, will not work. Often this will not be much of a problem – just unscrewing a few bolts will be enough. In addition, cleaning the intercooler yourself will require purchasing a high-quality cleaning fluid. As a rule, it is not cheap, so we do not recommend buying too cheap automobile products. As for washing with gasoline, kerosene, white spirit or other “folk” remedies in your case, it is advisable to get the opinion of an experienced professional on this matter.

Air filter clogged with dust

When the intake valves open, the connecting rod goes down, and a significant vacuum is created in the pipe connected to the outlet of the pan ventilation system. When the air filter is clogged, due to the difference in pressure in the pipe and the pan, gases escape much more intensely, taking oil particles with them. In this case, the efficiency of the oil trap decreases, and the lubricant flies into the intercooler. In addition, air deficiency affects the quality of the combustible mixture. The fuel-air emulsion becomes too rich, and lubricant particles that enter the combustion chambers further change the proportion of fuel to air.

Precautionary measures

In the process of internally cleaning the device from oil, you have to work with aggressive flammable liquids, and also take precautions so as not to damage the intercooler itself:

1. During mechanical cleaning, do not use hard brushes, knives or other devices that can scratch or bend thin soft metal parts.
2. You should work with gloves and avoid contact of aggressive substances with your body.
3. Follow safety rules when working with flammable materials.

If you have any doubts about cleaning this module yourself, you must contact the service center for specialist help. Neglecting intercooler maintenance can soon lead to a major engine overhaul.

Source