Oil Leak after Smash Repair - Pls suggest options

[Salty_Dog]

OK fellas, i told the missus to take the X5 to BMW for a smash repair.
Instead she took it to some country repairer that her insurance suggested.
Long story short, there has been an oil leak since the repair.

The front mounted Intercooler was damaged when struck by a small Kangaroo, it was still ok, but it got crushed and pushed back slightly.
As part of the repair, they either had it re-cored or replaced.

There is the vehicle history, now the problem.

Ever since the X5 had been picked up, there has been a small oil leak up near the front drivers wheel.
After 3 weeks, i ripped the splash gaurd off and identified the source of the leak.

It is where the Rubber hose attaches to the intercooler.










Now, i have 1 main concerns

1. Should there even be engine oil in the Air System!!

When we found similar in a friends Nissan 3.0d Turbo Patrol, the mechanic said, get that car detailed and sold!

Thanks for any help.
I am putting the cover back on and it will be going to back to the panel shop that did the work.

PS: I recently replaced the Airfilter and looked around the PCV valve, was oil locally around the valve, sadly i didnt have a replacement valve on hand.
But being the X5 is a 2006, it has the vortex style insert... Can i just remove it and clean ALL parts and replace it??
Will this possibly help with Blow-By getting into the Air Induction System?

[ants_oz]

Mate, after a Pootrol, you know it'll only be coming from one of two places: the turbo seals or the PCV. If it's PCV, potentially easy fixed. Turbo, I don't need to tell you....

I can only take the piss because my last ride was a D40. It's now gone. Enough said. Too fragile...

If you keep it, that intercooler needs to come out and be cleaned out. D40's were known to fill them with oil from the PCV. Now, I don't know much E53-specific info about the PCV's, but I fitted a chinese R&D (receive and duplicate) copy of a Provent to my D40 and instantly fixed the oil ingestion issue. I'd start by cleaning out the existing PCV and see what happens.

[Salty_Dog]

Cheers Ants, appreciate the input.
Mmmmm remove the Intercooling... oh dear
Well i guess i cant blame the Panel Shop for the oil, and i guess them not reinstalling the Charge Pipe correctly has lead to me being aware of this situation.

If its not one thing, it seems to be another with these babys.

But i am finding them very easy to work on.
Its just sad that all the work i do, seems to be correcting a paid professionals work
(like the incorrectly installed Air Filer and Air Filter cover)

Some people seem to suggest that Oil in the Air Charge system is 100% ok... I'm no expert, but i'd like to see "Just Air" in there

Can anyone else concur that i should remove the Intercooler and have it flushed out.
It was new on the Vehicle only 1 month ago (replaced at Smash Repair).
Not saying Ants is wrong, i can see the logic, i try and clean everything i touch when working.... It just might be a bit of a pain to remove the Intercooler

[ants_oz]

Mate, oil will just get burnt - and in the tiny volumes we're talking about won't even harm your emissions gear. Not that our diesels have much - no cats, no DPF....we're lucky.

But I digress.

I don't know the physical layout of the intercooler and pipes in the X5, but in the D40, the intercooler was the low point in the system - so oil settled there and over time.....glug glug glug. If the intercooler is high in the X5, all good.

That pic you posted - is that "hot side" pipe, or "cold side" of the intercooler. The reason I ask is because if it's a low point - either before or after the intercooler - all good! That's your collection point. Remove the pipe from the flange, wipe her out, some degreaser if you're keen, then reinstall.

[ants_oz]

just looking at the schematic on realoem. unfortunately, it looks like the intercooler is low mounted, so could possibly collect oil.

[Salty_Dog]

It is low mounted (front mounted)
In fact, i'd say that join is the lowest point in the whole system, as it lifts slightly in the tanks either side to enter the Cooling Element itself.

Not sure if its Hot side or the Cool side, i really didn't follow the pipe work, BUT, the other side has a Aluminium section of tube with a sensor mounted in it. It is not leaking on that side.

EDIT: Found this



Image lifted from here:http://www.estore-central.com/bmw-pa...-Air-Duct-Agr/

No. 3 connection is where ours is leaking dark black oil (small amounts)

[ants_oz]

I'm thinking turbo seals. But not knowing much about these beaties, don't know if it's common, worth fixing....usual decision matrix.....

The upshot - if it's "just" turbo seals and it's not using substantial oil, who gives a rats arse Drive it and love it. My D40 was no slouch (after I chipped it), but this thing sings!