Blocking the EGR valve on ZD3o DI 2003/ leaking turbo and intercooler

[vbowste1]

Hi all
After reading the thread about the EGR i have blocked it on my 1996 2.8 , and my was there some shit in the insert that i pulled out ( i removed the valve completely and there is a sleeve like thing in there that slides out it has an opening at the end and it was almost full of hard soot ) Wish it was blocked by someone when it was new.
Anyway my brother in law has a ZD30 2003 and we took the cover of the motor to find the EGR valve and im not sure where it is ......the forum photos show the valve on a 2.8 GU and i cant see one on the ZD30 can someone help.
Also we found that there was oil leaking somewhere around the turbo and the inter cooler had oilish stains around the intake on both sides of the cooler .......
Any ideas ??????
Regards Steve

[the ferret]

Here ya go mate.

[YNOT]

The attached photo shows the positions where you can block the EGR on a ZD30Di motor. The photo is of my 2003 3lt.

I can't be certain without seeing a photo (send them to me again if you're still having trouble) but it sounds like the intercooler is leaking. The oil you are (most likely) seeing is condensed PCV oil mist - the reason a lot of us fit PCV filters or catch cans.

Tony

[vbowste1]

Thats a very good diagram, i have looked at the tube going to the inlet and from that valve and noticed there where electrical wires plugged into the top so i thought id better ask before i tried anything.
Thanks so much for your help.

[vbowste1]

I was hoping you would say that, i have taken photos and will send them.
Thanks tony

[vbowste1]

Any chance someone can send a diagram of a catch can and explain what it does..??????
Cheers

[vbowste1]

I am trying to look at your photos of the ZD30 you sent and all i get is a message saying that i ether have not logged on ( which i have ) or i did not confirm my email, how do i confirm my e mail????
Sorry i know im a pain but i am a beginner and not very computer literate.
Cheers

[YNOT]

I am trying to look at your photos of the ZD30 you sent and all i get is a message saying that i ether have not logged on ( which i have ) or i did not confirm my email, how do i confirm my e mail????
Sorry i know im a pain but i am a beginner and not very computer literate.
Cheers

AB or Paul (Patch) could you look into this please.

Steve you are not being a pain, we were all new at this once. We're here to help mate.

Tony

[vbowste1]

Thanks , might also explain why i cant get a paper clip symbol?
I sent the photos to you, have you looked?

[YNOT]

That is the classic leaking intercooler on a ZD30. I'll dig up some older threads showing you options for replacement.
As I suggested earlier the oil is PCV (positive crankcase ventilation) oil mist.
In all 4 stroke engines there is an amount of combustion gas that leaks past the piston rings into the crankcase of the engine (known as blowby), also in the crankcase is oil mist caused by the engine oil being thrown around inside the engine. To stop the blowby pressurizing the crankcase the crank case needs to be vented, but venting those gases/emmissions upsets the greenies. To keep the greenies under control manufacturers run a hose (the PCV hose) from the rocker cover on top of the engine back around to the intake duct between the air filter and the inlet manifold, this allows the PCV vapours (a mix of blowby and oil mist) to be drawn back into the engine to be burnt.
One downside to this process is that the oil mist condenses and coats the entire inlet tract with a fine coating of oil, the oil that is now leaking from you turbo and intercooler.

A PCV filter or catch can fits in line with the PCV hose and seperates the oil mist and blowby. The oil is trapped to be drained later (can be plumbed to auto drain back to the sump in some installations) and the blowby is allowed through to be burnt. The greenies are still happy because the are no additional emmissions to the atmosphere...............unless you had a curry for dinner and are driving with the windows down but that's another matter entirely!

Tony