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turbo - oil pooling throughout entire intake - how to clean intercooler 900 1993

posted by  darmstrong on  Sat Mar 5 13:40 CST 2005
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last visit: Sat Sep 13 12:21 CST 2014
[RELATED]

My newly acquired 940 with Mitsubishi TD04H turbo has a number of small fluid leaks, so I started by investigating under the hood. I first cleaned out the engine breather. The small tube back to the intake manifold was completely blocked. The compressor bypass valve (CBV) was completely oil coated, so I cleaned it with Simple Green.

I then removed the metal tube between the short (4") vertically mounted hose coming off the turbo's compressed air outlet, and the intercooler. There was oil pooled on the lip of the turbo outlet where it met the hose. This explained why the CBV was oil-coated. There was also oil pooled in the hose leading into the intercooler, the hose leaving the intercooler, and the hose leading into the throttle body (maybe a tablespoon in each place).

I have to think that oil throughout the intake can't be great for the components after the intercooler - IAC valve, throttle body, even injectors. I have some questions:

1) The FAQ indicates this oil pooling isn't that unusual; any comments?
2) Would the small breather hose being clogged contribute significantly to oil pooling, or are there other causes?
3) I will clean out all the removable hoses up to the throttle body, and then clean the throttle body and IAC valve. Should I also clean out the intercooler? If so, how?

--
David Armstrong - '86 240(350k km?), '93 940T(270k km), '89 240(parts source for others) near Toronto






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