[MP81]

That looks like a nice failure...wonder if that part number is changed since the vehicle was released. Plastic is cracking?

 

[MP81]

I am not sure how to tell if it's a new part number. The OP hints that it may be.

I sure hope so - that's the kind of failure that shouldn't be happening.

 

[MP81]

This has occured with our two highest mileage CTDs. 158,000 and 186,000.

@diesel this looks like something that we need to write a specific thread about and place it as a sticky.

I'm guessing we will all encounter this mechanical failure in due time. In some ways a refreshing change from emissions system faults.

The duct is hard plastic, not rubber, isn't it? So it probably becomes brittle with the heat-cycling and cracks, perhaps?

 

[MP81]

I was wondering this myself.

I would believe that to be very difficult, due to direct injection, and the fact that diesel won't auto-ignite when it's not compressed.

 

[MP81]

Definitely follow your logic. Could that pop sound have been the duct coming off?

Plastic snapping in shear would make a lot of noise.

 

[MP81]

I am a bit confused though. When this happened, I had smoke and strong diesel fumes, but doesn't an intercooler cool the clean intake air?

Yes, it should only be compressed air from the turbo. That's a good point - you should not have had either...