Changing intercooler hose

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Optimus Prime

Well-Known Member
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Garden of England
Meant to post this a while back, but couldn't work how to add thumbnails to post. But done it now so here it is:

Intercooler hose rubbed through on engine cover fixing screw, while I was on a Sunday morning callout, 80 miles from home, and with a christening to go to that afternoon. Loss of power and an almighty sucking sound gave the game away.

Did a temporary fix with a coke can, some self almalgamating tape and some duck tape, which got me home.

Bought replacement hose from main stealer, and thats when the fun begins. The top clip is easy to undo, as access is easy. The bottom clip is an absolute c*nt, being right in the front beside the headlight with very little room. With apologies to all engineers everywhere, I managed to slip a small pair of pliers in the gap and undo the clip, 1/4 turn at a time, until it was loose enough to spin it round and undo it properly.

To get better access, undo the top clip first, then bend the hose down on itself and wedge it down the side of the dipstick.

Putting the new one on is easier, as you can position the clip where it is easiest to do up.

Then re-inforce the hose where it rubbed with an offcut from the old one, and hold in place with cable ties (metal are best), taking care not to do them up too tight and squash the hose.

except now the thumbnails are too big, so they're in the gallery. Would do it now, but warm wife waiting upstairs
 
Meant to post this a while back, but couldn't work how to add thumbnails to post. But done it now so here it is:

Intercooler hose rubbed through on engine cover fixing screw, while I was on a Sunday morning callout, 80 miles from home, and with a christening to go to that afternoon. Loss of power and an almighty sucking sound gave the game away.

Did a temporary fix with a coke can, some self almalgamating tape and some duck tape, which got me home.

Bought replacement hose from main stealer, and thats when the fun begins. The top clip is easy to undo, as access is easy. The bottom clip is an absolute c*nt, being right in the front beside the headlight with very little room. With apologies to all engineers everywhere, I managed to slip a small pair of pliers in the gap and undo the clip, 1/4 turn at a time, until it was loose enough to spin it round and undo it properly.

To get better access, undo the top clip first, then bend the hose down on itself and wedge it down the side of the dipstick.

Putting the new one on is easier, as you can position the clip where it is easiest to do up.

Then re-inforce the hose where it rubbed with an offcut from the old one, and hold in place with cable ties (metal are best), taking care not to do them up too tight and squash the hose.

except now the thumbnails are too big, so they're in the gallery. Would do it now, but warm wife waiting upstairs

While I was checking the engine compartment some time ago I noticed also the "impossible" position where that one clip was located and mainly for that reason I had a look at the underside of that big hose and noticed the screw underneath which could be dangerous. Therefore I put something between the hose and that screw..... (see also other post called "Hose problem"):)
 
Thinking outside the box:-


Buy new Hose Clips and cut the old one on an easy access flat area with a Dremmel. You're gonna junk the hose anyway.

Worked for me :)
 
Thinking outside the box:-


Buy new Hose Clips and cut the old one on an easy access flat area with a Dremmel. You're gonna junk the hose anyway.

Worked for me :)

Thats what I do!!

It's like that cos the nice dudes at the factory fit it all up on a bench/turntable thingy then the whole lot (engine,box,prop,rear diff,hubs etc.) goes into the body in one hit.
 
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