Has anyone done this

[disco_thrasher]

I am putting in a egr bypass kit in my td5 disco 2000 which has 236000k"s on it ,,,,,, i have alot of oil in the pipe coming from my intercooler going to egr unit , what i was wondering has anyone taken out there intercooler and cleaned it out ..if i have that much oil in the top pipe surely there has to be aload of it in the intercooler itself any recommedation will be appreciated
thanks kelvin

[alien]

Had a look here while trying to remember how to refit my radiator;)
Thanks Urban Panser:D

www.discovery2.co.uk / Workshop / Intercooler Cleaninr (http://www.discovery2.co.uk/intercooler.html)

Cheers.

[disco_thrasher]

Had a look here while trying to remember how to refit my radiator;)
Thanks Urban Panser:D

www.discovery2.co.uk / Workshop / Intercooler Cleaninr (http://www.discovery2.co.uk/intercooler.html)

Cheers.
wow awesome just what i needed thanks alot
from kelvin

[pohm66]

A couple of us used these instructions a few months ago and worked well just 2 observations came out of it though.

1) removing the grill is so much easier if you haven't fed the wiring for driving lights or antennas through it.;)

2) Make sure the couple of locating lugs on the bottom of the intercooler are set right before re-assembling.

We used Acetone as the solvent as it dries without leaving any residue. When we poured it out after swishing around the intercooler for a good few minutes it came out the colour of a weak tea. We both noticed an increase in the performances of our D2s.

[disco_thrasher]

yeah i was thinking that removing the grill on mines gonna be a big job on itself i was thinking of taping it to the bull bar,:confused: yeah i was told kerosene was good aswell ,how long did it take you guys

thanks kelvin

[scarry]

If you do a search on here,but i cant find it at the moment,Dave Blkn,has done it with the intercooler in place.

[Blknight.aus]

http://www.aulro.com/afvb/projects-tutorials/45041-egr-removal.html
and related to.
http://www.aulro.com/afvb/technical-chatter/45001-yet-another-egr-disposal-thread.html

[trog]

i am also interested in giving mine a clean out for the same reasons but cant get blacknights links to open blocked by avg. so is ths possible to do without removing or if removal is necessary are there any tricks special tools needed and about how much time needed for a very amateur "mechanic"?

[Blknight.aus]

a little bit of oil is normal, mainly because it comes in via the crank case ventilation system...

Mine was near on squeaky clean at the 100K km service but I advise flushing it out on a regular basis to stop excess corruption from slowing down its preformance.

My flush method requires several goes at it so in the order that Idid it in

1st flush is dieso
2nd is hot soapy water
3rd is hot water
4th is warm air for a couple of hours to dry it all out properly.

If you have any signs of goop or oil duing the hot water rinse repeat the whole process till thats coming out clean.

I used a large tower pipe on the inlet and outlet of the cooler and blew bursts of compressed air through from the lower of the 2 outlets to agitate everything as much as possable. The bursts of air were applied for each seperate fluid type.

If your going to that much effort ID also recomend that you goto the silicone hoses afterwards as Im fiarly sure that the existing hoses wont appreciate what happens very much. You should also fit blanking covers to the turbo outlet and inlet manifold

from

post 13 (http://www.aulro.com/afvb/624448-post13.html) of The EGR removal thread (http://www.aulro.com/afvb/projects-tutorials/45041-egr-removal.html)

[disco_thrasher]

So Dave you actually left your intercooler in its place for your flush instead of removing the entire unit