Air intake leak detected

[Muddy1987]

Hi guys recalling struggling here I’ve got a 2014 merc sprinter I’ve had a merc tech come out and change
EGR valve, cooler relief pressure valve, manifold all seals around it. Fuel filterx2. Turbo actuator valve. Connection piece coolant line. Still showing up as a air leak. HELLLLLP


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[Muddy1987]

Hi guys really struggling here I’ve got a 2014 sprinter 2.1, so far we’ve changed EGR valve, cooler relief pressure valve, manifold all seals around it. Fuel filterx2. Turbo actuator valve. Connection piece coolant line. Both turbo pressure solenoids. Please help as to what else I can do. It’s had several leak tests but no leaks apparent


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[LostKiwi]

Have you checked the turbo to intercooler and intercooler to manifold hoses?
Cracked intercooler?
Broken manifold bolt?

 

[Muddy1987]

It’s had a new manifold fitted today along with the seals around it. Hoses seem fine but the turbo intercooler hose seems like there is some play when pushed in and out.

So ordered that for tomorrow. Mechanic thinks it’s unlikely but need to eliminate


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[LostKiwi]

Intercooler hoses have a habit of developing hard to see splits.
Intercoolers can get salt corrosion or holes from road debris.

 

[Muddy1987]

Sorry for the daft question but if there was a hole or leak in the intercooler would it leak out air and potentially cause an air intake leak?


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[Muddy1987]

I’ve took the red turbo to intercooler hose off gave it a clean can’t see anything but ordered a new one just to eliminate as it moves more freely than it should


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[LostKiwi]

Sorry for the daft question but if there was a hole or leak in the intercooler would it leak out air and potentially cause an air intake leak?


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Yes

 

[ajlsl600]

"Showing up as air leak" where is that information coming from,, a code? Read on what ?

 

[mersum1es]

Air leak is detected if madd flow differs too much from other calculated values, possible culprits are dirty MAF, or actual leak somewhere (EGR, charge hoses, manifold bolt/gasket). Has the boost line been pressure/smoke tested? Can you try another MAF? All pressure sensors showing same ATM?

 

[Muddy1987]

"Showing up as air leak" where is that information coming from,, a code? Read on what ?

It’s showing up on the star diagnostic equipment. A leak was detected in the air intake system.


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[Muddy1987]

Air leak is detected if madd flow differs too much from other calculated values, possible culprits are dirty MAF, or actual leak somewhere (EGR, charge hoses, manifold bolt/gasket). Has the boost line been pressure/smoke tested? Can you try another MAF? All pressure sensors showing same ATM?

Initially the pressure air on the the diagnostics was showing less than it should but once the manifold changed it went to it true value. The only thing showing at -30 is the EGR when it should be +20-30 but that’s been changed parts from merc


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[ajlsl600]

It’s showing up on the star diagnostic equipment. A leak was detected in the air intake system.


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If yr sure there is no leak in the induction system .look at sensor providing the fault.does car have normal power output ? Is it in limp ?

 

[Muddy1987]

It drives ok sometimes up to 20 minutes then puts the fault code on and goes into limp mode. Even in limp mode it drives good up to 3000 rpm.

I can switch the ignition on and off and it goes out of limp mode but once the engine light comes on then the key trick doesn’t work.


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[Uncle Benz]

Have you tried replacing the air mass meter?

 

[Muddy1987]

No I’ve been told that’s fine as the I’ve reading is ok


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[Uncle Benz]

If you have smoked it and there is no leak it must be a calculated error. It isn’t to do with the boost side, as the errors are worded for intake pressure usually. The air leak errors are most often due to egr faults or sometimes the manifold bolt broken, but that usually gives multiple errors for boost pressure too. My hunch is on the air mass reading being slightly out of spec. If the fault only occurs while driving looking at the live data in the workshop won’t find it.

 

[Muddy1987]

I’ve just took out the air mass meter and it was dirty with a fly stuck in the where the copper wire is located. I’ve cleaned it out now and just waiting on a new intercooler pipe then will road test it


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[Uncle Benz]

Well that’s something! The air filter should prevent anything at all getting into the sensitive unit. Fingers crossed

 

[mattkh]

I’ve just took out the air mass meter and it was dirty with a fly stuck in the where the copper wire is located.

How did the fly go through the air filter.