Member Since: 30 Nov 2014
Location: Southend on Sea
Posts: 180
Intercooler Hoses, One simple one......
So decided to upgrade the Intercooler Pipes today as I recently purchased a Silicone set, ok they are Red which are unusual but I like to be different
Tools needed are Trim Panel Clip removal tool, screwdriver and 7mm Socket.
Also I had available a bag of spare clips just in case I had issues removing the covers.
Divers side is easy, turn steering to full Right hand lock, remove the cover held by 4 clips.
Undo the top and bottom jubilee style clips and remove the hose.
The clips stay with the pipes as they have a fold round element that has two small teeth that dig in the hose!
This new hose is easy to fit as many will agree, take less than 15 mins.
Passenger side is a slightly different beast, to gain access you need to remove the cover by the FBH exhaust, the upper front clip was missing on mine, as it not easy to get too!.
Now the fun starts as you need to gain access to the other end of the hose, this is buried in the engine bay, no possible access from above, so I started to release the inner wheel arch cover and eventually could see the clip and the end of the hose. Now unless you have the arms of a small child, with multiple joints and the strength of 10 men I resorted to removing the wheel arch trim, the inner wheel arch cover. Also I removed the lower section of the FBH exhaust. Only then could you undo the clip and prise the hose off.
Now the books always say refitting is the reverse and leave it at that, the hose and clip will wiggle in ok, but the hard part is to get it on the spigot from the turbo, there is very little room to get hands in and apply any type of pressure. Perseverance and working out how you can best get a grip of the hose will eventually see the hose put in place, the clip tightened, now the lower connection can be made, do leave this till the hard to connect end is done, as it does allow a “little” wiggle room.
Now return all the parts you took off to get the pipe connected and job done! About 4-5 hours including tea and lunch.
thanks for that, good clear photos and good advice.
I will be doing this job soon, so I think I will just bite the bullet and plan on pulling the front left wheel arch plastic cover straight away.
7th Jul 2016 1:23 pm
Henda
Member Since: 05 May 2016
Location: Gateshead
Posts: 473
Nice one
That's a to do job for me good photos nice explanation
Cheers All transmission oil replaced
3 flash indicators
All timing belts changed
EPB serviced
De cat fitted
Wind deflectors
De-tango done
Tints fitted
Egr blanked
7th Jul 2016 6:24 pm
deanslandy
Member Since: 17 Jan 2015
Location: nuneaton
Posts: 646
Belts, oil pump casing and water pump by Flack
Transmission flush by Geoff
7th Jul 2016 8:01 pm
woody32 Site Sponsor
Member Since: 11 Mar 2009
Location: Somerset
Posts: 3551
You've not finished yet what about the small turbo one Wanted D4s non runners pm for competitive price.
IID Pro MV License - D3/4 RRS - Enabling, Updates,Transmission flushing.
Mobile or workshop,PM for details.
7th Jul 2016 10:15 pm
Dai-Disco3
Member Since: 30 Nov 2014
Location: Southend on Sea
Posts: 180
Ah ha I have the small turbo one (in red ) but am definitely leaving that until it is needed, cannot even see where that hose is
7th Jul 2016 10:56 pm
woody32 Site Sponsor
Member Since: 11 Mar 2009
Location: Somerset
Posts: 3551
A very wise move I've got one to do Saturday so looking forward to it Wanted D4s non runners pm for competitive price.
IID Pro MV License - D3/4 RRS - Enabling, Updates,Transmission flushing.
Mobile or workshop,PM for details.
7th Jul 2016 11:07 pm
sailorboi
Member Since: 26 Oct 2012
Location: Bristol
Posts: 2020
Woody you told me you could not wait 07 Java Black TD V6 D3, EGRs Blanked, Tow bar, Full dog guard & divider, LED Spots , DRLs, GG ATs, RLD Sump guard, RLD Spare Wheel Protector, D4 LED Rear Lights, Limo tints on boot and Midnight tint on rear windows, Kenwood screen with Garmin nav, Rear cameras, D4 Steering wheel with flappy paddles, T-max split charge system, Tree sliders, Prospeed roof rack & Ladder, Alisport fast road inter cooler,
Massey Ferguson 35x
Sankey Narrow Track Camping Trailer (Gone but to a great home)
7th Jul 2016 11:18 pm
woody32 Site Sponsor
Member Since: 11 Mar 2009
Location: Somerset
Posts: 3551
Don't get your hopes up it may find its way out the door after 2 hours of cursing Wanted D4s non runners pm for competitive price.
IID Pro MV License - D3/4 RRS - Enabling, Updates,Transmission flushing.
Mobile or workshop,PM for details.
7th Jul 2016 11:23 pm
sailorboi
Member Since: 26 Oct 2012
Location: Bristol
Posts: 2020
If it does then Don't worry we will do as the Op says above and wait 07 Java Black TD V6 D3, EGRs Blanked, Tow bar, Full dog guard & divider, LED Spots , DRLs, GG ATs, RLD Sump guard, RLD Spare Wheel Protector, D4 LED Rear Lights, Limo tints on boot and Midnight tint on rear windows, Kenwood screen with Garmin nav, Rear cameras, D4 Steering wheel with flappy paddles, T-max split charge system, Tree sliders, Prospeed roof rack & Ladder, Alisport fast road inter cooler,
Massey Ferguson 35x
Sankey Narrow Track Camping Trailer (Gone but to a great home)
7th Jul 2016 11:25 pm
snow?wotsnow?
Member Since: 01 Nov 2009
Location: Somerset
Posts: 23
Hoses and Intercooler
I echo Dai-Disco3's guide regarding the nearside hose to the intercooler. Definitely need to remove the wheel arch shroud and go in from the side to get the new hose onto the swage.
I couldn't find the leak the was causing the whooshing sound under acceleration and seeing plenty of crud at the bottom corner of the intercooler, decided to switch that out while doing the 2 main pipes.
The guide said to prise out the rad-to-intercooler pins, with the intention of taking rad and intercooler out separately. The inner part of the pin came out OK but there was no way I could get the outer sleeve to release insitu, so I lifted both rad and intercooler out in 1 piece using a friction strap for overhead support while I pleaded with the metalwork to let me through. Note the double thickness of triplewall cardboard used to protect the fins of the a/c condenser during the operation. (Photos in my gallery)
I put the new intercooler back separately from the rad and had another fight to get the pins right as they went in.
Of course the whooshing had been coming from a hose split in the usual place but a 12-year old, 155k miles intercooler under the energised puff from a BAS remapped ECU was probably worth it.
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