Member Since: 21 Oct 2016
Location: kent
Posts: 13649
Hi
Thks and was indeed the pipe , Know there’s a rubber joint in there as well , alas hard to see and never know may have just come dislodged
Fingers crossed mate
23rd Dec 2018 8:48 pm
Discomadness
Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
That’s my thought also mate. I’ll have a quick go at in the morning before we set off. Wife is a nervous passsenger and car will be loaded with stuff so will be taking a gentle drive down the motorway anyway. I’ll let you know how it goes Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
23rd Dec 2018 9:42 pm
Discomadness
Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
Ok had a really good look. No unsecured flanges or fittings. That connection on the intake pipe was not connected properly and the rubber seal was a bit kinked so thought ah ha ! Put it all back together properly. Tested. Still exactly the same. That weird squealy hissing under load, give it some wellie, limp mode. My best guess is there’s a crack in the alisport intercooler. I just don’t know what else could cause that noise under boost. I’m going to have to just try and take my time with it now and then start really ripping into it when I’m back. Getting really despondent with this car now. One fault after another after another all the bloody time. Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
24th Dec 2018 11:59 am
Discomadness
Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
Just had dad Rev the car to around 2500/3000 rpm while I look around. I can hear the pressure escape at the bottom end drivers side of the intercooler and the area has got some oily residue there. The pipe is tight and clamped on so looks increasingly like a crack or flaw on the intercooler. On the positive that’s a fairly easy fix, got a few friends with the correct welding equipment.Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
24th Dec 2018 1:02 pm
Discomadness
Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
We’ll just got home from west wales. Managed the trip there with one instance of going into limp and then home without doing it by driving as gently as I could, going to pull the intercooler tomorrow for a look.
The fun never stops. Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
26th Dec 2018 10:09 pm
Daveheeson
Member Since: 26 Dec 2018
Location: West Yorkshire
Posts: 5
I have had a similar situation under load foot down uphill and it powers along lovely then as you reach the brow and ease off the throttle it throws a fault and its like the turbo just turns off, restart and all back to normal done it 2 or 3 times this year always same circumstance i think i will start looking at the hoses and clamps.
26th Dec 2018 10:34 pm
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20731
Discomadness wrote:
My best guess is there’s a crack in the alisport intercooler
I’ve seen a couple of Allisport cooler welds crack... My D3 Build Thread
Member Since: 13 Aug 2010
Location: Wiltshire
Posts: 13909
I had this with my Alisport IC. Had to buy another.New Defender L663 110 SE (known as Noddy!)
Sold Volvo XC90 R-Design (known as Basil)
Sold - D4 HSE (Known as Gerty)
No longer the Old Buses original owner
231,000 miles and counting
05 S manual owned from March 2005
D4 Face lifted
Still original injectors and turbo
V8 Front brakes
BAS Remap, Allisport Intercooler and deCat
EGRs blanked
T-Max split charge
Hanibal Expeedition rack
Prospeed ladder
Duratrac tyres
IID BT
BAS FBH control
26th Dec 2018 10:47 pm
Discomadness
Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
Have you Mikey ? That’s very interesting you say that. I thought it seemed a bit “thin” but thought that was my heavy handed engineers paranoia. Maybe not. I’ll report back as soon as I know. 100% need to change the 5 injectors though this rough idle/white smoke thing is bloody embarrassing. Gearbox is 100% faultless though mate. Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
26th Dec 2018 10:47 pm
Discomadness
Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
Moo wrote:
I had this with my Alisport IC. Had to buy another.
Bought mine second hand. Be bloody annoyed if a £540 intercooler failed ! As Mikey has said he’s seen a few and alisports “lifetime warranty” small print is more than a bit evasive !Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
26th Dec 2018 10:48 pm
Discomadness
Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
Daveheeson wrote:
I have had a similar situation under load foot down uphill and it powers along lovely then as you reach the brow and ease off the throttle it throws a fault and its like the turbo just turns off, restart and all back to normal done it 2 or 3 times this year always same circumstance i think i will start looking at the hoses and clamps.
I’ve replied to your pm mate. Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
26th Dec 2018 10:49 pm
Discomadness
Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
Pulled the intercooler, several cracks around the mounting bracket welds. One was near to coming away altogether. Not what I was holing for. Looking at it though it’s bound to happen being mounted in this way. I think a serious repair and modification are in order. Put the old one back on for now. Car back together, still going into limp mode. What now. Seriously losing my cool with this thing now. I don’t think even lemon is a good enough nickname.
Quick edit. I’ve noticed that the car seems to hang onto a gear as if it doesn’t want to change up before throwing the “special programs off” and goes into limp.
Should I be looking to give the ecu’s a reflash ? Don’t really know where to go next with it.Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
27th Dec 2018 7:08 pm
ClassikFan
Member Since: 02 Nov 2016
Location: Surrey
Posts: 1027
I had different fault codes to you:
P023D-21 (6Cool Manifold absolute pressure - turbocharger/supercharger boost sensor A correlation - General signal failure - signal amplitude<minimum
P0101-17 (6Cool Mass or volume air flow - circuit range/performance - General electrical failure - circuit voltage above threshold
but after a while I noticed that the gearbox seemed a bot odd in the few seconds before the fault was thrown.
My fault was fixed with an £18 bottle of turbo cleaner but I have that the cure for P132B is a new turbo - sorry to say.
27th Dec 2018 8:28 pm
Discomadness
Member Since: 19 Jan 2015
Location: Caerphilly
Posts: 2256
Hi classicfan.
I’ve done a few searches on here and they seem to come up with turbo also. I hope not. The costs on this thing are getting out of hand !
Jarrod
Current : D3 2007 HSE - AKA the lemon
-beanie grille
-detango with led bulbs
-club body off rebuild. TWICE.
27th Dec 2018 8:32 pm
ANother
Member Since: 28 Jul 2018
Location: None
Posts: 179
Just had a catch up on my favourite thread and sorry to read of your troubles you've worked so hard on this and spent a small fortune. Hope your lucks better in the new year.
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