Damaged Intercooler

[tim-spam]

Recently had a stone (or something) clout the intercooler right next to the header on the offside. It appears to have sightly dislodged the header, because an oily liquid drips out of it (this almost certainly comes from the EGR system) - just enough to make the undertray dirty, but not yet enough to be visible underneath the undertray, although it seems to be getting slightly worse. The leak is not enough to cause the oily liquid to spray out under pressure, and there is no measurable loss of boost pressure.

Due to the

[johnb80]

The airflow from the intercooler is into the inlet manifold so why would EGR be responsible for the oily liquid? More likely the oily liquid is coming from the turbo seals assuming that it is the intercooler we're talking about here. It's not by anychance the Airconditioning condenser unit is it? That too sits at the front, looks like a radiator and would have an oily liquid going round.

 

Regards - John

[tim-spam]

No, it's definitely the intercooler. I should have said CCV instead of EGR - the CCV system is upstream of the intercooler, and is responsible for the oily liquid. By the way, the oil consumption is very low (at least 5000 miles per 1/2 litre).

As I said, the amount of liquid is small, but is enough to make the upper surface of the undertray dirty. My main concern is that small leaks have a nasty habit of becoming larger, so if there is a way of resealing it (by, for example, squeezing the crimping tabs a little), I'll give it a go - it's just that I don't want to make it any worse, and was wondering if anyone else has had a similar problem.