looking for a plan B

my 300tdi is losing oil most of it is going into the intercooler, i have had the turbo checked its fine,doesnt look like crank case pressure,the oil return pipe is clear and the breather is not blocked,they are the only 3 reasons we can come up with for it to put oil into the intercooler and does not appear faulty
Anybody got any experience of a similar problem
i am stuck for ideas

Have you blocked the EGR Valve???

there is no exhaust gas return valve i had it removed and silicone hoses fitted
could that be it

magsnemma said:

there is no exhaust gas return valve i had it removed and silicone hoses fitted
could that be it

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unlikely as thats upstream of the intercooler

does breather go into air box, which then feeds turbo, which then feeds intercooler, cos tiny amounts of oil pass from breather to turbo to cooler,

Yer not overfilling it with oil are ya? That then does as above, sperts out breather round cooler n burns the stuff

magsnemma said:

there is no exhaust gas return valve i had it removed and silicone hoses fitted
could that be it

Click to expand...

Nope if egr is gone only way oil can get into intercooler is thru turbo. or HGF blowing oil into manifold. which is then been fed thru the turbo into the air inlet? Is it smoky when running?

how would egr fill intercooler with oil ?how did you check turbo

breather goes into pipe between air cooler and turbo and there is a mist of oil in it , the oil runs out of the pipe on the other side of the turbo , no i am not over filling the oil i checked for that, its not smoky at all when running starts like a dream no signs of piston wear to build up pressure
sorry if im daft but what is a HGF

Head Gasket Failure. But it doesn't sound like it from what your describing??? I'd say crankcase pressurisation

jamesmartin said:

how would egr fill intercooler with oil ?how did you check turbo

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I was thinking oil leaking into exhaust from some where hgf?? and passing into intercooler thru egr??

james martin, i had the turbo to a specialist who put it on his machine and ran it for 2 hours no leaks no nothing , he even declined to refurb it as it didnt need it
In reply to your question about the EGR, i dont know we have looked at all the logical (or what we think are logical) answers we are now looking at the illogical

we thought about crank case presurisation but dont think so the oil filler cap we found is bust but there is no oil being forced out through it and surely the pressure would go through a 1.5 inch hole before it went through a 3/8 hole

never illogical ,does it breathe with filler cap removed ,you could remove pipe from cyclone and bung hole in intake pipe ,route pipe from cyclone so it doesnt drip down engine ,you can run engine with pipe to intercooler from turbo off and see what oil passes through ,try it with breather pipe on and off

youve just about nailed what our next steps are, we found there was no gauze in the breather so we are correcting that just to say we have done something as well.
i was hoping someone was going to give me a magic bullet