Tip & How-To about Mazda 323

Intercooler and EGR problem

Sometimes people get this low power and smoke problem in a turbodiesel car with an intercooler. Once it is not your injectors or turbo gone, you can solve it without buying new intercooler or EGR valve. You can actually clean them. It does take few hours of your time but cost you much less. All you need is few hours of time, a gallon (4-5liters) of diesel and same of petrol (better naphta but its hard to get in some places). First you need to take of the intercooler which might involve removing front bumper in some cars. Once you have it out, put it on the ground (do not damage the core) and fill it up with diesel. Cover the inlet and outlet (best with balloons) and leave it for few hours. Meantime you can take care of the EGR valve and inlet manifold. Using petrol and soft brush clean all visible parts but do not fill EGR with petrol too much as it must be complete dry before you put it back. Do same with the inlet manifold, just clean that oil/smoke build up. It is slagish but getting rid of it will add your engine extra kW/Bhp and some life to it. When you finish cleaning and drying the EGR and manifold your intercooler should have been a little "washed" by the diesel inside, shake it a little bit, the "balloons" should stop the diesel from spilling out, and leave it for 2-3 hours. After that time empty the diesel out of it and fill it with petrol (naphta) to wash out remainings of dirt and diesel, do it couple of times while shaking until the liquid is more cleaner, than dry the inner of the intercooler, make sure it is completely dry and as clean as possible as anything that will be wet with diesel may cause some serious problem. After drying and putting everything back, leave it for a while before starting the engine, this is to make sure that whatever remained undry will vapourize. Remember when you start the engine do not rev it up just leave it at idle for 10-20 minutes. This will add temperature that will dry up anything you've missed and not cause any damage as there will be not enough pressure. After this operation you will notice a change in the car's performance.

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my 1992 nissan terrano blows to much black smoke .how to fix this .some say i have unbirt fuel?


if diesel and turbo , check turbo operation of for holes in the intercooler
if turbo or naturally aspirated check/ replace injector tips as black smoke indicators squirting and not atomizing
if petrol check for excessive fuel pressure, faulty injectors , leaking injector seal
regardless of petrol or diesel --black smoke indicates incorrect air / fuel ratio ( too much fuel) so injectors, intercooler, bad turbo or blocked air cleaner are all candidates for the fault

Dec 04, 2016 | Nissan Terrano Cars & Trucks

1 Answer

Why the isuzu 2.5turbo diesel intercooler loose power and smokes when it warms up


what ISUZU what body? what year, and what country.
we cant guess all that?????? Injection system types vary by ALL THAT.
that can be lots of things
but the turbo , stops the smoke.. (adds air during times when old non turbo diesels smoked normally)
it could be a bad turbo or a leaking injectors
why not get a mech to service the car.? guessing will not work.

Feb 26, 2015 | Isuzu Cars & Trucks

2 Answers

Hi, I have a 2005 hilux 3.0 turbo Diesel , it started blowing blue smoke at startup from cold at 130,000ks . Once it warms up a little it clears.


There can be several reasons for this. You can have worn valve stem seals on the valves, which may change with warm oil, or you have worn oil rings in the cylinders.

A compression test when the engine is cold would reveal if the piston rings are worn. Another possibility could be a bad head gasket which leaks oil when cold and then seals when the heads warm. A compression test would also diagnose this.

Aug 27, 2012 | Toyota Hilux Cars & Trucks

1 Answer

saab 9-3 diesel 120, My turbo charger is load and whe given a bit of throttle 2 overtake ect.. lots of black smoke piles out the back and sometimes e turbo will stop workin untill u tur the car of and back on, any ideas?


The turbo will not cause black smoke. White smoke, yes, if its passing oil into the engine, but not black.
First check that the air intake and filter is not blocked, check that the air hoses from the turbo and intercooler are not collapsing when given throttle.if thats ok, then get the injectors tested, if they are ok then you need to get the injection pump serviced. Black smoke is a result of overfuelling, either by the poor dispersal of fuel from the injectors or the pump, or blockage of air into the engine on the intake system.
Hope that helps

Feb 16, 2010 | Saab 9 3 Cars & Trucks

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