Member Since: 29 Jan 2021
Location: Monmouth
Posts: 10
D4 Intercooler elbow box blown off
Hello Newbie here. Driving up a long hill tonight and loud ‘pop’ followed by change in air intake noise and went into limp mode. Got home and found the Intercooler elbow box, or air vent box had come off the throttle body
I’ve managed to put back on securing the clip properly and wiped away a small amount of oil.
It’s all fine now but wondering what caused it? Clip not fitted back properly by garage after cam belt change, or is there too higher pressure in there caused by something more serious?
Grateful for suggestions before I spend money getting it checked out. Thanks
29th Jan 2021 12:45 am
M3DPO
Member Since: 22 Sep 2010
Location: Notts.
Posts: 8247
Highly likely not fitted correctly, they have to be pushed on at a slight angle and then twisted horizontal before the clip is pushed home, no chance of them blowing off if fitted properly.
Small amount of oil is normal, just clean it out before fitting.It can when others can't,
It will when others won't,
It goes where others don't.
2011 D4 XS - OBD port protection, RLD spare wheel protector, All LED interiors lights, Timed Climate enabled, iiD tool paired.
2011 D4 Landmark - Stolen from same dealer before I paid for it
2011 D4 GS - Stolen whilst at dealer ... All LED interiors lights, DRLs, Spare Wheel protector.
1996 300Tdi - Eaten by tin worms
29th Jan 2021 9:32 am
Reallyfree
Member Since: 29 Jan 2021
Location: Monmouth
Posts: 10
M3DPO wrote:
Highly likely not fitted correctly, they have to be pushed on at a slight angle and then twisted horizontal before the clip is pushed home, no chance of them blowing off if fitted properly.
Small amount of oil is normal, just clean it out before fitting.
Thanks appreciate reply. Yes it was a fiddle to get back on but once I figured how the clip worked with the lugs, I sussed it. I’m guessing with that very elaborate clip fit it’s designed to cope with some decent pressure and as you say can’t come off.
29th Jan 2021 11:48 am
Reallyfree
Member Since: 29 Jan 2021
Location: Monmouth
Posts: 10
Hardware wrote:
Was the lower left corner bolt fitted?
Yes and it was tight because I removed it to get the box back on. Whole box was at an angle touching fan blades. Must be some serious pressure to do that and make the champagne cork pop sound.
Now convinced clip wasn’t fitted properly thanks to you guys.
29th Jan 2021 11:51 am
AwB
Member Since: 25 Sep 2017
Location: London
Posts: 12
Hi. Late to the party, but thought I'd chime in. The same thing happened to me (Landmark D4) while on a run from Hampshire to Fife in that small window last summer when you still could. I got the reduced performance warning and a noticeable decrease in mpg, but no limp mode.
The elbow connector had come off, but was still roughly in place as the clearances are quite tight... there was a light oil spray residue that lead me there.
In my case, the elbow connector kept popping off as there was a hairline crack in the lip of the connector, just where that retaining clip passes through the body to grip the manifold body inlet (on the top left of the photo, away from the bolted part). This probably gave enough flex that any boost pressure would overcome the clip.
So it might be worth checking for cracks.
Acquired a new one from the nearest dealer for <£100. Happy days. The kids got bored of hearing what an ace mechanic their dad was!
4th Feb 2021 3:29 pm
UffBrock
Member Since: 18 Mar 2011
Location: Oxfordshire
Posts: 157
And me. Three trips to the dealer before it was finally fixed!.
4th Feb 2021 8:31 pm
Reallyfree
Member Since: 29 Jan 2021
Location: Monmouth
Posts: 10
Thanks everyone. Well it’s been over two weeks and all good. Thanks for the tipoff on hairline cracks, although just seems was incorrectly fitted.
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... All LED interiors lights, DRLs, Spare Wheel protector.
