I was doing some work to my truck (New EGT + boost guage + SD manifold) so I had the passenger fender liner out. I noticed quite a bit of oil on the outside of the intercooler pipe. It has never blown off and it almost looks like a combination oil/soot. Is this normal? I am surprised it is blowing out there that much.

take it to the dealer. There is a TSB for this. They need to remove the hose, clean it out, and use a sealant and new type hose clamp to fix the problem. Nothing worse than a new car pissing on the driveway!! The oil is coming from the crankcase ventilation.

Can anyone post the TSB? Hopefully it is something I can do myself.

my repair order references repair per document #1561746. All data doesn't show a TSB, but when I brought it in to the dealership they immediately mentioned a bulletin on the problem. Since it is new, don't mess with fixing it yourself, have it fixed and documented under warranty.

Thanks. I'll see what I can come up with.

Max, the TSB doesn't do anything to correct the oil being in the hose...it just calls for more sealing to prevent external oil residue.

I'm not going to worry about it on my truck, which has the same problem. The oil is still going to be in the intercooler tube.

Maybe we need a drain :D

I wonder if we need to get rid of the PCV valve.

Big Blue has had that since almost day one. We have taken him twice and it just came right back:rolleyes: Doesn't seem to be hurting him any :D

As long as it doesn't blow it off I guess it should be ok. Odd that it would leak past though.

You might want to take it off, clean it off, spray it with hair spray, then put it back on tight.

I might give that a try, thanks.

So Tony, did you try fixing this yourself (with a sealer or ? )or go to the dealer?

Neither yet. I will probably wait until the next time I have the fender off. It's not dripping on the floor yet so it's not bothering me :p:

Tony and All,

I just had this TSB repaired on mine. They had to order a special silicone sealer from Izuzu and it required a minimum of 8 hours dry time. NO MORE LEAKY!!


Here is a copy of the bulletin:



Turbo Air Charge Cooler Hoses Oil Seepage , or Blows Off on Acceleration - kw black smoke boost noise turbocharger clamp leak oil LLY 6.6 whistle P0299 low intake surge no power #PIP3068B - (Nov 1, 2004)

Turbo Air Charge Cooler Hoses Oil Seepage, or Blows Off on Acceleration.



The following diagnosis might be helpful if the vehicle exhibits the symptom described in the PI.

Condition/Concern:

Oil seepage from turbo air charge cooler hoses or hose blowing off during acceleration. Possible DTC P0299.

1.
2. Due to the closed PCV system on the 6.6 LLY engine, it is normal to have oil residue in the air charge cooler hoses and pipes.
3. The oil will migrate to the lower areas of the air charge cooler system and may cause customer concerns of oil seepage.
4. This may also cause the air charge cooler hoses to blow off when turbo boost is high.

Recommendation/Instructions:

1.
2. Do a visual inspection of air charge cooler connections and hoses.
3. Replace air charge cooler hoses, pipes, or clamps if damaged.
4. Properly clean all oil from air charge cooler pipes and hoses.
5. Air charge cooler hoses and pipes are marked for proper installation. The hoses are marked with ENG, DUCT, or CAC (charge air cooler) the hoses and pipes must installed correctly. The engine side is marked ENG, the duct side (the aluminum pipe) is marked DUCT, and the charge air cooler side is marked CAC.
6. Apply a very thin coat of sealer part number 97720043 to the air charge cooler hose connections.
7. Install hose and properly torque air charge cooler hose clamps to 8 Nm (70 lb in).



Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance.

Models:

(04 05 6.6 LLY C2 C3 K2 K3 Chevrolet Silverado GMC Sierra) and (04 05 6.6 LLY C4 C5 D4 D5 E4 E5 Chevrolet Kodiak GMC Topkick)