Vw T5 Intercooler Hose Diagram

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stevolution View Drop Down

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Topic: turbo pipe blew off...lots of q's too
Posted: 04 Sep 09 at 03:24

hi guys, this is my first post, i'm excited to see what it's like...

main issue.... i was driving along and i lost all power, limped into garage, realised turbo pipe at the lower right of engine bay had popped off. it was very awkward but i managed to get it clipped back in. i was working at the time, behind schedule, losing sunlight and i managed to drop the little rubber seal. i didn't have the time or light to get the seal back on. i was able to drive it for the rest of the day at least but the van was making an airy pffffffffffffffffffff sound and i'm on about 50%power.

when i put the seal in, is this really going to fix this problem? is it possible to cram dirty big jubilee in there?

other thing i noticed is it was a little bit oily in there, is there cause for concern?

t5 06 plate, 174 remapped to a supposed 209bhp. this took place at 72k, van has now covered 80k

also, i dunno whether to repost other questions as i'm a noob here but i'm just gonna fire away with my other questions........

without going mental, is there any other mods that could free up some extra bhp? is there anything holding it back? exhaust? cat? filter?

last question for now, i'm a mobile valeter, i carry around 2-500kg a day. no matter how i drive, it seems i only get on average 80 miles for 20 quid of diesel. I don't have a computer i'm afraid. is this normal? apparently the remap was supposed to give me more power and economy but to be honest the only thing i noticed was a wad missing from my wallet. (i went to a place called powertune and he takes my software, beams it down to somewhere in birmingham, they come up with a map and beam it back, no rolling road or anything)

any help would be great guys

cheers

steve

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Vanorak

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Posted: 04 Sep 09 at 08:34

Welcome Steve That hose blew off on my van too. Also the the top end of it blew off (twice)! I think if you just replace the seal it will happen again. Jubilee clips won't fit. You have to replace the hose.

What happens is the giant paper clip that holds it in engages with some tin lugs on the metal band bonded to the hose. Under extreme boost (made worse if you carry big loads, or in my case towing) the clip starts to strip the lugs. Here is a pic of the top part of that hose on my van which is doing its best to blow off yet again!

I don't see the point in keep buying hoses if they all eventually go the same way so I pushed the hose back into place put a large cable tie round either side of the clip then used two others to draw them together. This seems to be just enough to stop the hose working on the lugs and stripping them. Crude but it'll do until I work out something more elegant.

Yours being chipped probably made it worse but I think it's just a poor design since mine isn't chipped. Someone did say a while ago that the new vans now have a jubilee clip! But I don't think we will be able to convert ours to that system.

Some oily residue is normal inside the hose. Mine is just like a thin film.

Edited by T5 TDI - 04 Sep 09 at 08:56

2004 2.5 174

mcguyver

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Posted: 04 Sep 09 at 10:15

Is this another benefit of the 84ps engine? It hasn't got enough boost to blow the turbo pipe off

mac

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Posted: 04 Sep 09 at 12:23

Mine did the same when I gave it too much welly from cold at a junction. The design is a bit flawed, I don't see any good reason why it is not more permanent than a 'paper clip'.

I had mine fixed but am not convinced that the same won't happen again. I like the cable tie idea, may add this on as a precaution if I can get to the turbo.

05 T5 LWB Panel van

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Vanorak

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Posted: 04 Sep 09 at 13:07

I suppose I was a bit mean calling it a 'paper' clip when it's a well made bit of spring steel. The clip is ok but the metal band round the hose isn't up to the job. I think my cable tie bodge might eventually let go in the heat under the bonnet but no sign of that in the last 2000 miles since I did it. Anyway, cable ties are cheap! Here is a pic of the bodge, I won't be looking for patents on it

They always call it a turbo hose but it's nowhere near the turbo. It's at the front of the engine. It runs from the EGR/changeover valve (the connection shown in the pic) which is easy to get at, down to the intercooler connection on which is awkward to get at. Although I had the bottom end blow off like on stevolution's van it has never come off again. Luckily it's always the top end that wants to come off these days.

2004 2.5 174

stevolution View Drop Down

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Posted: 05 Sep 09 at 02:07

thanks for the info guys, glad i'm not the only one. i think i might have a got at a bodge. i'm tempted to get a thin layer of rubber inbetween the plastic and the metal then get a large jubilee. i'm never gonna be comfortable on long runs from now on. i'm gonna have to fabricate something.

i'm not sure if it's just in my head but i dunno if it's driving/boosting the same, maybe i'm just paranoid. thing is though, i can't believe the seal, it's awful, boost must get past that surely.

markwindsurf View Drop Down

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Posted: 04 Nov 09 at 21:04

If you drill this between the edge and the seal, collect swarf don't let it drop into turbo, then a single self tapper just near where the clip has been into the inner pipe collar. Service technician at VW was very impressed with how efficiently it sealed and will never come undone again.

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Posted: 04 Nov 09 at 21:36

I thought about doing something like that Mark but I didn't want to drill the EGR/changover valve. I don't no why though, I suppose I was vainly hoping that it might help the chances of a future goodwill claim

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markwindsurf View Drop Down

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Posted: 05 Nov 09 at 17:43

Vanorak, I am an automotive design engineer by day and the retention method is poor at best, the clip is not sufficient to retain the hose when you look at the boost pressure it is retaining, a quick glance at the hose when someone is reving the van will show you the pressure build up in the pipe. Having spent the money putting a new pipe on I am still not convinced I would not have been better checking the self tapper every year, and instead spent the money on posh diesel.

Edited by markwindsurf - 05 Nov 09 at 17:44

mick g

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Posted: 05 Nov 09 at 19:13

I had one blow off my 2004 174 ps van less than a year after I had it... Twas replaced by VW and all was fine. Just had a squint at my 2008 beast and the same pipe now has a big, bad invincible mo fo jubilee clip fitted instead.. .. Surely they retro fit the hose with this type now?

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Posted: 05 Nov 09 at 19:30

I bow to your superior knowledge of course But I think the design would work fine if they hadn't made the lugs (that the clip engages with) out of that soft metal. The clip is clearly made of quality steel and has the right tention, making it a perfect to strip the cheap 'punched' lugs of the band that is bonded to end of the turbo hose when extreme pressures occur.

I might as well get the drill out now since I don't think there is much 'goodwill' left between me an Volkswagen UK anyway.

2004 2.5 174

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Posted: 06 Nov 09 at 22:04

mick g wrote:

Mick, I haven't seen that new clip yet but I don't think it could be easily retro-fitted. It was spotted early on by err.. () I can't exactly remember who but one of the usual supects. For a Jubilee type clip to work it would need some kind of ridge to clamp behind, or maybe it's a Jubilee clip with some kind of 'bite' itself somehow?

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Jason Statham View Drop Down

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Posted: 17 Oct 10 at 20:29

Ouch My 174 has just popped the intercooler pipe off, big whoosh followed by a nice pop! pushed it back on then a couple of miles later same again. sick as a Blackpool Donkey or what!!!! further investigation shows the actual clip has snapped in half. so i took the other ones off and found those partially snapped,( one leg missing off the clip) it amazes me that these snap like that! can you buy just the clips or do I need to remortgage the house and buy new hoses etc!? Its also quite sooty inside the butterfly valve area, is it worth taking it off and giving it a good clean out with some solvent/petrol before reassembling it all? If I approach my friendly VW dudes are they likely to send out the clips on good will or will they tell me to get lost? Has anybody bought the new pipes, how much are they, and can they be retro fitted to an 06? Cheers all!

If it's got tits or wheels it's gonna give ya grief..... if it has both it'll be the death of ya!

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Posted: 17 Oct 10 at 21:50

Can you post some pics Jason? There is no chance of the clips snapping in half on mine. Maybe you have the later jubilee clips... If your van is an '06 that sounds too early for those. Perhaps you have aftermarket hoses and they are also now failing? Definitely some pics needed

For anyone looking in here with the early clips see energysolutions excellent cheap fix on the (often missed) 'Modifications' section here. http://www.brick-yard.co.uk/forum/forum33.html

Edited by T5 TDI - 17 Oct 10 at 22:02

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Jason Statham View Drop Down

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Posted: 31 Oct 10 at 22:34

wiill do I have ordered new clips from Heritage in Westbury. ( superstar Tim in service is the boy) delivered to my door all 5 clips £5.20. Awesome. they are like C clips although i think that the lugs on the lower pipe are worn so might have to replace that as well!
Cry