OK, as many will know, the inlet/boost pipe fittings used on the VAG TDIs are prone to popping apart.
If the two small retaining lugs on the end of the pipe get worn or damaged, it's often a downhill slope - once it's happened, it's quite likely to happen again. Each time the joint comes apart, the more damage gets done to the lugs, so it's a vicious circle.
And because of the design of the joints, you can't use jubilee clips...
I've recently had the problem on my Passat (PD130).
One of the pipes runs from the engine, to the top of the (side-mounted) intercooler.
I started having allsorts of problems recently - hesitancy, smoke etc but oddly, no warning lights, fault codes or noticeably power loss either. I could hear the turbo much more clearly than usual.
Turned out the hose into the top of the intercooler had partially blown off - one side had blown out, but the other side was still held in, so it was at an angle and although losing a fair bit of air, not enough to trigger any faults.
I refitted the pipe and the clip, however I noticed one of the pipe lugs was quite worn.
Took it out for a drive, and it popped straight off again.
Options:
1) Buy a new pipe, and new clip. Pipe will probably be quite pricey. Nowhere open I can buy a pipe from before I need the car on Monday.
2) Try an alternative means of pipe retention...and if that fails, revert to option 1.
So - an alternative means of pipe retention...
I refitted the pipe in it's normal position.
Using a dremel with a 2-3mm drill bit, I drilled two holes through the outer plastic housing of the "socket", going just far enough in to mark the metal of the pipe tip.
Disconnected the pipe, stuffed tissue in the 2 open pipe ends to keep swarf out.
Used the dremel to drill through the metal pipe tip where the marks were.
Cleaned everything up.
Refitted the pipes and horseshoe clip.
Screwed 2 small self-tappers through the holes in the plastic housing, and through the metal pipe end inside.
So - pipe is held in by the horseshoe clip, and also 2 screws.
An easy job to do, and went out for a drive giving it full beans up numerous hills - and it's still in place.
Because the rubber seal is right at the end of the pipe tip, the holes are "behind" the airtight seal - so if I do ever replace the pipe, I can just slot the new one in with it's horseshoe clip and no problem with the holes being there.
Also, the 2 screws are easily removable should I ever need to remove the pipe.
Let's see how it goes in the longer term, but this could be a cheap & easy fix for knackered pipe joints....
If the two small retaining lugs on the end of the pipe get worn or damaged, it's often a downhill slope - once it's happened, it's quite likely to happen again. Each time the joint comes apart, the more damage gets done to the lugs, so it's a vicious circle.
And because of the design of the joints, you can't use jubilee clips...
I've recently had the problem on my Passat (PD130).
One of the pipes runs from the engine, to the top of the (side-mounted) intercooler.
I started having allsorts of problems recently - hesitancy, smoke etc but oddly, no warning lights, fault codes or noticeably power loss either. I could hear the turbo much more clearly than usual.
Turned out the hose into the top of the intercooler had partially blown off - one side had blown out, but the other side was still held in, so it was at an angle and although losing a fair bit of air, not enough to trigger any faults.
I refitted the pipe and the clip, however I noticed one of the pipe lugs was quite worn.
Took it out for a drive, and it popped straight off again.
Options:
1) Buy a new pipe, and new clip. Pipe will probably be quite pricey. Nowhere open I can buy a pipe from before I need the car on Monday.
2) Try an alternative means of pipe retention...and if that fails, revert to option 1.
So - an alternative means of pipe retention...
I refitted the pipe in it's normal position.
Using a dremel with a 2-3mm drill bit, I drilled two holes through the outer plastic housing of the "socket", going just far enough in to mark the metal of the pipe tip.
Disconnected the pipe, stuffed tissue in the 2 open pipe ends to keep swarf out.
Used the dremel to drill through the metal pipe tip where the marks were.
Cleaned everything up.
Refitted the pipes and horseshoe clip.
Screwed 2 small self-tappers through the holes in the plastic housing, and through the metal pipe end inside.
So - pipe is held in by the horseshoe clip, and also 2 screws.
An easy job to do, and went out for a drive giving it full beans up numerous hills - and it's still in place.
Because the rubber seal is right at the end of the pipe tip, the holes are "behind" the airtight seal - so if I do ever replace the pipe, I can just slot the new one in with it's horseshoe clip and no problem with the holes being there.
Also, the 2 screws are easily removable should I ever need to remove the pipe.
Let's see how it goes in the longer term, but this could be a cheap & easy fix for knackered pipe joints....