ZD30 Intercooler oil leaks

Submitted: Sunday, Aug 19, 2007 at 19:39

ThreadID: 48853 Views:9607 Replies:9 FollowUps:4

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TheMajor

Hi Forum
I was just checking some threads and I noticed the numerous recent problems being once again experienced with the ZD30s. After reading the threads I took the cover off the intercooler as I noticedoil was dripping from one of the rubber hoses above the turbo. What a filthy mess under the cover! Oil caked on, particularly the outlet hose, it makes makes me furious as I have just had the 120,000km service at nearly $1,000 and I asked the dealer to check for any oil leaks as I had found a couple of drops on the garage floor, the reply from them was "no oil leaks found, nothing wrong" and they have even entered this on the invoice. It just seems you are treated with contempt and if you say something you are treated as a nuisance. I wonder if anyone out there could help me in explaining what the problem might be with all the oil around the intercooler hoses under the cover. I have also experienced a lack of power on one occasion when I was going up a small hill and of course, I though the worse that it had blown up, however after I took my foot off the acceleraor it came good. I would appreciate any advice in regards to the oil mass under the intercooler cover. I thought these were only air hoses. I am about to leave on a trip through the Simpson Desert so I am feel nervous about going.
Thank you in anticipation.
The Major

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Reply By: Member - Captain (WA) - Sunday, Aug 19, 2007 at 20:27

Sunday, Aug 19, 2007 at 20:27

Hi Major,

The lack of power that was returned when you backed off the accelerator is the turbo boost exceeding max pressure and setting the turbo vanes to minimum. This over-pressure is not recorded in the ECU and is reset immedialtly you take your foot off the accelerator and why the power returned after backing off

Given the problems you have described with your intercooler and the overboost issue, I suspect the turbo is overboosting on a regular basis hence why the leaks on the intercooler. I would get this checked out by a reputable specialist (NOT Nissan) and particualrly monitor turbo boost pressure. Backing off the turbo is an easy job, a turn on the vane adjuster - just need to know what the pressure is.

Cheers

Captain

AnswerID: 257975

Follow Up By: hl - Sunday, Aug 19, 2007 at 20:48

Sunday, Aug 19, 2007 at 20:48

Hi,
Some oil in the intercooler is quite normal. It is not good, but they all do it. It comes from the PCV system. Combined with the Exhaust Gas Recirculation in the ZD30 engine, it makes for quite a mess in the intake system after a while. It is a fairly big job to clean up properly, and would not normally get done in a routine service.
As for the occasional overboost, especially when changing up on a hill, that is very common too and could be fixed as described above.
Cheers

FollowupID: 519259

Reply By: TheMajor - Sunday, Aug 19, 2007 at 20:54

Sunday, Aug 19, 2007 at 20:54

Thanks Captain for the comments, I imagine it is still light over there in the West, I still have fond memories of the Army camp on the beach. Also thanks for your input hl. After reading all the problems the ZD30s have I thought the SeriesIII had been refined from these problems. I am still worried about heading into the Simpson though but I paid the extended warranty to get the 150,000 kms or 5 years. Once again Thanks Very Much
The Major

AnswerID: 257983

Follow Up By: Member - Captain (WA) - Sunday, Aug 19, 2007 at 21:38

Sunday, Aug 19, 2007 at 21:38

Hi Major,

While others have their doubts, I believe the series III to be a very reliable engine. Its not without its niggling problems, but then neither is ANY engine.

I would be far more worried about my tyres than my engine, tyres are a real and regular issue, series III engine failures are a very rare beast (unfortunately not the same comment for series II engines).

But one thing I would do is block off the EGR. Apart from emmission issues, there is no good reason at all for exhaust gas recirculation and I believe this is the root cause of series II engine failures.

Cheers

Captain

FollowupID: 519269

Reply By: TheMajor - Sunday, Aug 19, 2007 at 22:32

Sunday, Aug 19, 2007 at 22:32

Thanks Captain, I will take it on board what you say. I appreciate the advice.
Regards The Major

AnswerID: 257997

Reply By: traveller2 - Monday, Aug 20, 2007 at 08:25

Monday, Aug 20, 2007 at 08:25

Make sure that the intercooler isn't cracked as this will allow the oil to 'escape' from inside of the traunking to drip all over the motor.
Intercooler cracks are very common on the 3 litres and is caused by the overboosting.

AnswerID: 258021

Follow Up By: gompy - Monday, Aug 20, 2007 at 13:13

Monday, Aug 20, 2007 at 13:13

The first thing I would do is check if the MAF sensor is dirty, this can cause overboosting, if it is not I would buy a new one anyway to keep in the car in case you need it in the Simpson!

FollowupID: 519334

Reply By: Truckster (Vic) - Monday, Aug 20, 2007 at 13:21

Monday, Aug 20, 2007 at 13:21

I would take it back to who ever robbed you 1000 and demand some action = do it when they are busy, and demand to speak to the dealer principal.

AnswerID: 258070

Reply By: TheMajor - Monday, Aug 20, 2007 at 16:02

Monday, Aug 20, 2007 at 16:02

Thanks Traveller2. I have been all over the intercooler and I don't think it is cracked. It seems that all the oil is being blown out from the join of the rubber hoses onto the steel sections. I have tightened the clamps up and am only it doesn't blow the hoses out now. Thanks for the advice mate.
Also thanks for your comments and it is good to hear from you Truckster, the trouble is mate, when you have a major service it all depends on the dealer but they charge between 800 and 1000. As my car is still under warranty - I took out a 5 year/150,000km it is part of the deal that the major service is done by Nissan every 40,000 but with the 10,000 services I have been informed by Nissan Australia that I can do them myself and keeping all receipts to prove I used the proper oils. They have even charged me to fill up the windscreen wiper water reservoir, even though it was full they said they drained it and put in their stuff!
Regards
The Major

AnswerID: 258098

Reply By: TheMajor - Monday, Aug 20, 2007 at 16:04

Monday, Aug 20, 2007 at 16:04

Thanks Gompy, Where is the MAF? I know it might sound a silly question with all you fellas in the know but my time was before computers and sensors. Thanks for the information mate
Cheers
The Major

AnswerID: 258099

Follow Up By: Member - Bentaxle - Monday, Aug 20, 2007 at 22:25

Monday, Aug 20, 2007 at 22:25

The MAF (Mass Airflow Sensor) is situated in the air intake linr above airfilter housing. they are a constant sourcr of annoyance and at $300+ not easy on the pocket

May the fleas of a thousand afghan camels infect the crutch of your enemy and may their arms be too short to scratch.

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FollowupID: 519471

Reply By: TheMajor - Tuesday, Aug 21, 2007 at 10:14

Tuesday, Aug 21, 2007 at 10:14

G'day Bentaxle
Thanks for the infomation mate, I know exactly where you mean now. All this high tech stuff is beyond me, my old Toyota 60 Series I can take apart with my eyes shut. Once again thanks very much I will get a spare before I go. I will be off the air for a couple of months now on my trip. Thanks very much to everyone who has give me advice and assistance I really appreciate it.
Regards
The Major

AnswerID: 258238

Reply By: Member - Bentaxle - Tuesday, Aug 21, 2007 at 21:20

Tuesday, Aug 21, 2007 at 21:20

Major
This usually happens if the intercooler has been rmoved and replaced, the seal beteen the rubber hose and the metal sleeve, to fix wipe and clean the inner portion of the rubber hose and the outer portion of the metal sleeve with meths or something similar that evaporates off quickly and rejoin and tighten clamps. the problem is that no matter how clean things may seem this is not the case, the slightest miniscule particle will allow the oil vapour to pass, no matter how tight the clamps are hence the mess

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AnswerID: 258378