Member Since: 28 Aug 2006
Location: Mid-sussex
Posts: 2021
Strange Burn to Air Intake - thoughts?
I am about to have a go at getting my glow plugs out. With the oil filter off and looking down at middle plug on driver side I noticed a strange hole. It’s as if something hot was held against the plastic causing it to melt. I can’t tell whether the air could leak in or out. There is no hole visible but there could be pin holes.
Click image to enlarge
Click image to enlarge
The LR dealer did replace a couple of plugs many years ago before I knew better! And before I started my own servicing. Wondering if there used something hot and melted the plastic.
Any thoughts on the hole and if there are pin holes there , what symptoms.
I will fill with something - any suggestions.
Thanks in advance.
Barn1e2005, TDV6 S, Auto, 190k miles, owned from new, V8 Brake Upgrade, Nancom Evo, RLD protector, BAS EGR blanking & Remap, separate ATF cooler, changing all the fluids ahead of time.
1st Aug 2018 11:30 am
Gareth Site Moderator
Member Since: 07 Dec 2004
Location: Bramhall
Posts: 26705
That could have been caused by hot gasses escaping from a glow plug? I have to admit i'm not sure what we are looking at here. If it is the inlet manifold, then I would be very wary of that, in case a piece breaks off and gets taken into the engine. Likewise if you fill it, there is possibly a danger of the filling material getting sucked in.
1st Aug 2018 11:52 am
L319
Member Since: 14 Dec 2013
Location: Herefordshire
Posts: 2080
Looks more like a stress fracture to me , is anything attached at that point.
1st Aug 2018 12:05 pm
Pete K
Member Since: 15 Jan 2016
Location: GL
Posts: 10373
Inlet manifold have been known to crack. (more the 3.0 and maybe in a different place)
Maybe damage by a drill chuck?
1st Aug 2018 12:10 pm
M3DPO
Member Since: 22 Sep 2010
Location: Notts.
Posts: 8120
Definitely caused by hot gases escaping on the compression stroke from either the glow plug or injector, it usually leaves a hard brittle glossy coating that is very difficult if not impossible to remove as it burns on, it could have been done a while back, looks like you have had a lucky escape.It can when others can't,
It will when others won't,
It goes where others don't.
1st Aug 2018 1:23 pm
Barn1e D3 Decade
Member Since: 28 Aug 2006
Location: Mid-sussex
Posts: 2021
Thank you for replies. Here is a wider view of what I described as the air intake. There are two boxes on each side of the engine and they are the windscreen side of the box that contains the EGR butterfly.
Click image to enlarge
It faces the oil filter housing that has no damage. The melted area is not in line with the glow plug below. I still think the dealer may have used a blow torch or something whilst trying to get the plugs out. The plastic block that holds the three glowplug connectors is not damaged.2005, TDV6 S, Auto, 190k miles, owned from new, V8 Brake Upgrade, Nancom Evo, RLD protector, BAS EGR blanking & Remap, separate ATF cooler, changing all the fluids ahead of time.
1st Aug 2018 2:14 pm
M3DPO
Member Since: 22 Sep 2010
Location: Notts.
Posts: 8120
You may well be right, one thing we are in agreement with it was caused by a flame, it hasn’t cured itself so someone knows about it and surely if it was there when the glow plugs where changed the dealer would have informed you It can when others can't,
It will when others won't,
It goes where others don't.
1st Aug 2018 4:44 pm
jeeptj
Member Since: 22 Jun 2018
Location: Washington
Posts: 34
In the second pic, it looks like the manifold is broken?
And that oil cooler and breather is a to get out isnt it.
it's early in the morning and I may well be half asleep yet but …
A looks like a crack to me
B looks like a threaded hole
has something been fitted in the hole and overtightened/knocked … causing the crack ?.
Dean
====================================
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
2nd Aug 2018 6:08 am
Barn1e D3 Decade
Member Since: 28 Aug 2006
Location: Mid-sussex
Posts: 2021
Hi Dean
I will take another look this morning. Don’t think it’s a drilled hole. The crack may just be shadow of the flange of melted plastic. But I will look again. Thanks for the another perspective. All rather puzzling.2005, TDV6 S, Auto, 190k miles, owned from new, V8 Brake Upgrade, Nancom Evo, RLD protector, BAS EGR blanking & Remap, separate ATF cooler, changing all the fluids ahead of time.
2nd Aug 2018 7:31 am
Barn1e D3 Decade
Member Since: 28 Aug 2006
Location: Mid-sussex
Posts: 2021
I have had a poke around. No cracking of the plastic. Just melting. No visible wholes either. When I have “finished” the glow plugs job I will make a fibre glass shell over it to make sure it’s air tight.
I am also going to write up my experience of trying to change the plugs. This is likely to include putting the drilling out of two / three plugs to a specialist. As I write this, I am 24 hours into spraying them with Kroil releasing oil, tapping the hex nut, and gently applying pressure in both directions. So far, two can be undone 2 1/2 turns and two are still stuck. The two that move are the easy to reach middle ones !2005, TDV6 S, Auto, 190k miles, owned from new, V8 Brake Upgrade, Nancom Evo, RLD protector, BAS EGR blanking & Remap, separate ATF cooler, changing all the fluids ahead of time.
2nd Aug 2018 11:26 am
jeeptj
Member Since: 22 Jun 2018
Location: Washington
Posts: 34
A little heat helps a lot with stubborn glow plugs, but need a small hot flame like oxy acetylene welding torch but not a fiece welding flame, keep in moving around and work.glow plug in and out not just trying to unscrew.
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to get out isnt it.
... All LED interiors lights, DRLs, Spare Wheel protector.
