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Strange ball in 300tdi intercooler !


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Hi guys newbie to the fórum here, did search but found nothing so far so hope I am in right section.  We had a turbo failure on our 95 Series 1 discovery, we fitted new one all seemed ok. Then lots of blue smoke, back to workshop and looked at cleaning out intercooler (oops should hv down it when we changed the turbo I guess.....). Funny thing is there seems to be a strange hard ball like object rattling around inside the inlet tank of the intercooler, too large to come out..... any ideas? 
 

thanks  Paul

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Its tempting to suggest that Big Beetle Bert has escaped but as you probably don't get UK tv it will fall flat  :ph34r:. The only thing possibly in there that might rattle around is a baffle plate, have you got A/C? do both inlet and outlet connect the same side? if you have the standard vertical one then There shouldn't be anything that I can think of. You need to get what ever it is out because it will retsrict flow.

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The only thing I would suggest is a build up of oil and carbon for whatever reason that has balled up and got bigger with use or someone has stuffed something in to block an exit point to check for leaks and subsequently forgot about it far fetched I agree but stranger things have happened regards Stephen

Edited by Stellaghost
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Thanks Blanco, no, not a baffle plate, if anything it looks like a round stone too big to come out (hence too big to have gone in unless was there at manufacture . .  It is difficult to see maybe it's a ball of previously molten turbo (!).  Well we will have to pursue further...    here in Angola (relatively) "hi tech" companies doing intercooler repairs thin on the ground.

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Get it to one of the stubs and try and break it up to get it out to analyse it 

I suspect ally TIG facilities are thin on the ground where you are ....

We are all going to be interested to see what it is ☺️

Steve b

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13 minutes ago, Bowie69 said:

You only need someone with some TIG skills to cut it open, remove, and weld back up, wouldn't take too long.

Aluminium brazing does with a blow torch should do it, JB weld also araldite Regards Stephen

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On 11/11/2020 at 11:09 PM, steve b said:

I suspect ally TIG facilities are thin on the ground where you are ....

We are all going to be interested to see what it is ☺️

Steve b

Angola is oilfield country. Plenty of skilled welders around there, just got to find them.

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