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Lost power. Found that the intercooler pipe was fractured (A common problem I understand) but it was also blowing out oil. I found that the intercooler and associated pipes have oil in them, which I assume is not right. Question is - what caused it in the first place ? and how do I clean the oil from the intercooler? The turbo still spins ok when the engine is ticking over. We did notice that the oil on the dipstick was above max when we checked, so wondered if someone had overfilled it and if that might be the root cause. Hope someone out there can help. Don't really like the idea of a new turbo. (Incidentally - have had the intercooler pipe welded up )
 

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I have an 04 c max 1.6 diesel. 75000 miles. Been a good car. I had a problem with the last mot. struggled on emissions. I just passed however there was quite a noticeable exhaust reside when accelerating. This might not seem relative to you problem at present but bear with me.

I bit the bullet and took it to the local ford dealer who put it on the diagnostic. Diagnosed malfunction on the mass air flow meter caused by oil contamination. They fitted a modified pipe which comes from the rocker cover into the intake system. The modified pipe was to stop oil entering the inlet manifold system. Fancy piece of pipe which knocked a good hole in £60.

Ford cleaned the air flow meter with brake cleaner and the problem was sorted. So in the first instance you need to find out if you have the modified pipe fitted. You could tell a difference in the way the car drove after that.

Not bad service for a Ford dealer.

Good luck

Geoff
 
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