TD5 Smoke screen

Hey all,

My TD5 seems to be getting smokier. It's a D2a with a Graeme Coopers 'chip' and I've already fitted BAS's silicone hoses.

I've cleaned the MAF and MAP sensors with CRC cleaner and checked all the hoses and doesn't appear to have helped much. While doing so I noticed that there is an oily residue on the rigid bit of tubing connected to the silicone hoses between the turbo and the intercooler. I have the silicone hose on the intercooler side clamped on to the tubing where there is a large indent on the tubing. Can anyone tell me if this is correct or should the clamp be placed on the silicone hose side of the indent (hope this makes sense!!).

As long as the hoses are over the raised lip, at the very end of the pipe and on far enough to fit the hose clamp, then that is all that is required. Maybe a couple of centimeters.

If you can see oil on the steel section of pipe then this tells me that the hoses are loose and the oily residue from the intercooler is escaping. Re tighten them and clean the area and check again after a while or replace clamps with new ones.


If the hoses are all in good condition, then your smoke issue will be from something else

Oil seepage around turbo/intercooler hoses/ducts is normal for an older motor.
Exhaust smoke - when? on acceleration? Is your air filter OK?

Yep definatly go silicon, the delaminating seams to be more common with the D2a td5s'. Mine had no delamination after 260kms even, but replaced with silicon ones anyway, plus they look siiiic :D

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Originally Posted by Hendrik

Yep definatly go silicon, the delaminating seams to be more common with the D2a td5s'. Mine had no delamination after 260kms even, but replaced with silicon ones anyway, plus they look siiiic :D

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Thanks for that - only the turbo pipe duct to intercooler hose delam'd -

Have ordered new silcone hoses from England - in the interim instituted a temporary fix by inserting an internal spiral made up out of 3mm fencing wire - yet another 'bush mechanic trick' to add to the list.

Motor runs better than it's ever run since I've owned it - had 180 k and now 205 k.

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in the interim instituted a temporary fix by inserting an internal spiral made up out of 3mm fencing wire

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wouldnt you want it on the outside of the hose?? to stop the hose expanding?

cheers phil

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Originally Posted by discowhite

wouldnt you want it on the outside of the hose?? to stop the hose expanding?

cheers phil

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If the whole flex duct was expanding, as hypothesised by you, then we would be loosing turbo pressure and the flex duct would be a throw away.

The delam occurs on the inside between the inner 2 layers of flex duct - they cop the full heat.
The outer 2 or 3 layers stay together and hold pressure - they are cooler and therefore stronger.

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Originally Posted by Daniel

If the whole flex duct was expanding, as hypothesised by you, then we would be loosing turbo pressure and the flex duct would be a throw away.

correct, if a hose that contains pressure expands then you loose pressure. like a weak brake line and the fix is often bradided lines, and the braid is on the???outside, to stop the hose swelling. so again i still cant see why you would put the wire coil on the inside of a turbo hose on a td5:eek:

The delam occurs on the inside between the inner 2 layers of flex duct - they cop the full heat.
The outer 2 or 3 layers stay together and hold pressure - they are cooler and therefore stronger.

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cheers phil

Sorry, I assumed that you read the above posts fully - just to fill you in, the flexible duct between the metal duct and the intercooler had delaminated internally (as they seem to want to do) causing a large bubble that expands when its hot and closes off the air flow (internally).

The solution (bush mechanic) was to puncture the bubble and insert a spring wire coil internally into the duct to stop the now loose flap of duct material from closing up the flow.

A brake line is a hose that usually fails by loosing pressure leakage externally.
Any decent brake hose is multiple layer braided and I've also seen them fail by internal delamination causing lack of braking on the circuit that they feed.

If my intercooler duct had failed as you describe it, then I wouldn't have had the smoke screen effect - just increased smoke when the ECU couldn't cope with the sensor inputs relating to air flow/pressure/temp into the intake manifold.

My smoke screen was severe and sometimes accompanied by an exhaust explosion.
How severe? - when follwing at 100 kph and 50 metres behind - total non visibility of 3 lanes of road way immediately behind my td5. James Bond would've been proud of its effectiveness!

sorry mate it wasnt that clear in my head, you had me myfed as to what this flexable duct was?? no one uses that term here.
usually when the hoses fail the hose delaminates, the pressure gets between the other layers and being thinner now due to the delamination the hose swells and you loose pressure whilst retaining the fuel delivery hence the smoke.