Boost/Charge/Intercooler Pipe.

[AndyC567]

Hi All,

I was driving home this afternoon and my Sport PD130 mad made a big bang and wouldn't go at all

Looking in the mirror I could see smoke, and when I pulled over there was a horrible smell.

Anyway, wasn't far from home so nursed it back to take a look.

What has happend is the big black pipe that runs accoss the top left side of the engine and down behind the front drivers side headlight had popped off at the bottom. I think some of the noise I was hearing was due to it then rubbing on the alternator belt !!

So a quick search on here has revealled that it could be a common problem, and that the pipe goes under many names such as Boost/Charge/Intercooler pipe !!

It looks like 3 bits, a plastic pipe in the middle with rubber curved pipes at either end. I am hoping to replace the lower rubber curved pipe behind the headlight.

I am a bit confussed though, as many on here refeer to having to remove the under tray to replace/repair the boost pipe with jubillee clips ??

As I am desperate to get it fixed and get the car back on the road has anyone ever fixed this, and if so how ??

Thanks guy's.

 

[cactusjack]

Bumper off, headlight out, then wrap the hell out of it with speed/aluminium tape then jubilee clip round each end. Should hold until an upgrade can be sourced.

 

[AndyC567]

Bumper off, headlight out, then wrap the hell out of it with speed/aluminium tape then jubilee clip round each end. Should hold until an upgrade can be sourced.

Thanks..

I was affraid that the bumper and headlight may have to come off, so busy tomorrow then !!!

Actually, I have since spoken to a mate who is a Merc Technician and he says if I get a new pipe (the bottom rubber curved bit with the metal collars on each end) then it will simply just push in below the headlight and the same to the plastic middle bit of the pipe.
He reckons if I can source a pipe tomorrow it will be a 5 minute job to push it all back together !!

Anyone got any more thoughts on this, price or part number would be good ?

Thanks again...

 

[Blanco92]

Your Merc tech mate sounds like he knows what he's doing.

The same pipe became disconnected on my dad's T5 TDI, the metal lugs you talk about had just worn away to nothing. It didn't bang, smell or anything like you say but it was way down on power.

Haven't a clue about price or part number, I'm sure the parts guy on the desk will know what you're on about. The equivalent part for dad's T5 cost £46 though, would expect something similar for yours sadly

 

[cactusjack]

Give Dave @ Sere a shout. Look for his forum on here. Expensive iirc?

 

[cactusjack]

Better off sourcing an upgrade from SFS or something. Do a quick search on here, it's a majorly common problem. As the man above said, the metal lugs wear down. Be careful though, as the plastic coupling on top of my intercooler had broken so simply sticking a new pipe on just wouldnt cut it. Tape, jubilee clips and tie-wraps all round!

 

[AndyC567]

Update on my car...

Went to my local TPS and picked up a new bottom section of the pipe.

Part number 6Q0145834D (£26.58 + vat).

Separated the 3 sections of the pipe by releasing the clips which was easy enough..

I can see why it popped out, as the metal lugs on the collar were worn away, easy to see when compared to the new one.

I wiped some oil arround the O-rings on the collars of the new pipe and simply pushed it down behind the headlight into the the intercooler flange and heard it 'snap' into place. A quick tug confirmed it was well fixed. Then attched the middle plastic section which runs up along side the alternator pulley, and again that easly snapped into position. The top bit (again rubber with collars) was more of a fiddle as had to attach it to the centre plastic section and also the fitting along the top of the engine (close to the oil filler cap).

All done, took about 5 mins as my mate said !!

Took car for a test drive and it is fine again, totally different to how it was last night, what a difference a rubber pipe makes..

Thanks for your help guys.

 

[lusty2zero]

very common problem my FR one is shagged on the bottom intercooler connection so have cobbled it together at the mo with hose clips. Samco do a kit it's £288 for the 2 intercooler hoses SFS also do a very similar looking kit a bit cheaper THS223 £245

 

[cactusjack]

Update on my car...

Went to my local TPS and picked up a new bottom section of the pipe.

Part number 6Q0145834D (£26.58 + vat).

Separated the 3 sections of the pipe by releasing the clips which was easy enough..

I can see why it popped out, as the metal lugs on the collar were worn away, easy to see when compared to the new one.

I wiped some oil arround the O-rings on the collars of the new pipe and simply pushed it down behind the headlight into the the intercooler flange and heard it 'snap' into place. A quick tug confirmed it was well fixed. Then attched the middle plastic section which runs up along side the alternator pulley, and again that easly snapped into position. The top bit (again rubber with collars) was more of a fiddle as had to attach it to the centre plastic section and also the fitting along the top of the engine (close to the oil filler cap).

All done, took about 5 mins as my mate said !!

Took car for a test drive and it is fine again, totally different to how it was last night, what a difference a rubber pipe makes..

Thanks for your help guys.

Did this come with the metal clips to hold it in place? My pipe is split now and clip snapped ages ago so need new ones.

Cheers

 

[metakim]

Update on my car...

Went to my local TPS and picked up a new bottom section of the pipe.

Part number 6Q0145834D (£26.58 + vat).

Separated the 3 sections of the pipe by releasing the clips which was easy enough..

I can see why it popped out, as the metal lugs on the collar were worn away, easy to see when compared to the new one.

I wiped some oil arround the O-rings on the collars of the new pipe and simply pushed it down behind the headlight into the the intercooler flange and heard it 'snap' into place. A quick tug confirmed it was well fixed. Then attched the middle plastic section which runs up along side the alternator pulley, and again that easly snapped into position. The top bit (again rubber with collars) was more of a fiddle as had to attach it to the centre plastic section and also the fitting along the top of the engine (close to the oil filler cap).

All done, took about 5 mins as my mate said !!

Took car for a test drive and it is fine again, totally different to how it was last night, what a difference a rubber pipe makes..

Thanks for your help guys.

Just happened on my car yesterday. I also had a 130 mile journey ahead of me, which was no fun... It was the same lower bit near the head light and everything!

I looked up the part number you said, it was this bit right?

ebay.co.uk/itm/VW-Polo-SEAT-Ibiza-Intercooler-Pipe-1-9-TDI-ASZ-BLT-Engine-6Q0-145-834-D-/221170451777?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item337ec94541

Thanks

 

[AndyC567]

I looked up the part number you said, it was this bit right?

http://www.ebay.co.uk/itm/VW-Polo-SEAT-Ibiza-Intercooler-Pipe-1-9-TDI-ASZ-BLT-Engine-6Q0-145-834-D-/221170451777?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item337ec94541

Thats it, exactly the bit I fitted to my car..

If you look at the metal flange around the rubber, you will see that the lugs will of worn on the old one causing it to pop out..

The new pipe simply 'clicks' back into place.