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.
on Feb 04, 2010 | Mazda 323 Cars & Trucks