Just had the 60 thou service done on my '07 FL2 and thought I'd share this. A few days before a new noise appears - a "whooshing" from the engine bay when under load, about the same duration as you'd expect the turbo to be doing it's thing.

As suspected, the guys at the garage found a split in the lower intercooler pipe set and said a replacement was needed. Searching forums, there's lots of similar about the FL1, not much on the FL2. Also, there wasn't any power loss, black smoke or other symptoms, apart from the noise.

£45 for a part 'seems' reasonable. What I didn't expect was the fact the bumper and headlights had to come off to get to it. Apparently, the jubilee clips are impossible to get a screwdriver too as they are all facing the wrong way!

Fair play, all done and now back on the road. Though it does seem like taking the back doors off to let the clutch out.

PHarCAS wrote:

£45 for a part 'seems' reasonable. What I didn't expect was the fact the bumper and headlights had to come off to get to it. Apparently, the jubilee clips are impossible to get a screwdriver too as they are all facing the wrong way!

Fair play, all done and now back on the road. Though it does seem like taking the back doors off to let the clutch out.

A check of the warranty history on mine revealed an intercooler pipe split in the past. So its not uncommon. I had the same thing go on a truck I was driving once - it was deafening! No power on hills either. (on the truck it was a 4" bore pipe ) 10MY (Sept 09) TD4 HSE Auto in Stornoway Grey (Now Gone)

08 FL2 TD4 SE Manual in Rimini Red (Now Gone)

in fairness taking the bumper and lights off isnt a big deal At work
At home

"I can't always believe facts I read on the web" - Charles Dickens

winner by default of the tractor vs caravan race