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Thread: Intercooler pipe popping off, how do they secure?

  1. #1
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    Intercooler pipe popping off, how do they secure? and is oil in pipe bad?

    My T5s Intercooler pipe keeps popping off. It's the one going from Turbo to intercooler and it's the end going into intercooler. It has some sort of pressed metal fixture around/connected ar the end of the rubber pipe, this then goes in a hole on the intercooler. It's getting dark now so I can't see until morning. But is there some sort of clip I've lost or is there a screw or something I'm meant to do up, or does it twist and click in or something. Or am a self tapping screwing it back in?
    Naturally it's easter sunday tomorrow.
    Thanks again for any assistance here.
    So I figured out how to clip it back in or so I thought. It popped off again. Do the clips wear out or something? So annoyed at such a stupid design, or me being more fool than it is fool proof.... Please tell me if there's a key step I'm missing.
    Also another question. Should there be oil in the mentioned pipe? and how much would be a concern? I doubt it's pooling as such, but a 1cm finger wipe would be a full wet finger tip.
    Last edited by YoYo; 04-04-2015 at 04:43 PM.

  2. #2
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    Pretty sure it has a clip. maybe it has become dislodged. I the day light I reckon it'll be obvious. Should be no need for self tappers
    .. Gavin

  3. #3
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    Pulled the grill off to get more light in. It is the same sort of weird clip that connects the other ends of the hoses. Not sure how it works. Feels very lightweight and I'm not sure what keeps it in the closed position. But I'll give it a drive and see.
    Drove it, didn't hold it on. Not sure if I'm using the clip wrong, but fairly certain it's either A a really ***** design, or B designed to only last a certain amount of time.
    I'll try find info on how the clips work until I can try have a better look tomorrow. Where I need to examine pipe connection is the hardest to see one though, and I'm reluctant to open another pipe incase it weakens the clips grip.
    Happy to look like an idiot if anyone can shed some light on how these clips and pipe connections work.
    Last edited by YoYo; 04-04-2015 at 04:36 PM.

  4. #4
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    Had exactly the same problem is it the connection at the battery end or at the top end near the opening lever fitting ? if so it has a circlip which grips the alloy housing . When the pipe pulses back wards and forwards a small amount it wears the side of the alloy allowing the clip to release. I got sick of it doing it and decided I had a better method of securing it . VW will want an arm and leg for the alloy part so I just fitted two small screws into the housing and that was 7 years ago and its still perfect . some photos for you click on the photos to see more detail .
    Intercooler pipe popping off, how do they secure?-20150404_164619-jpg
    Intercooler pipe popping off, how do they secure?-20150404_164551-jpg
    Intercooler pipe popping off, how do they secure?-20150404_164534-jpg

  5. #5
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    Yes is that type of clip. But it's the other end of intercooler where it goes into intercooler. It'll be a real PITA to put a self tapper in. Is the metal part on the actual hose aluminum or steel? Will I have to pre drill it? Won't that put filings into intercooler intake(I think it's intake end)(non battery side).
    Curse you VW.
    Last edited by YoYo; 04-04-2015 at 07:35 PM.

  6. #6
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    Alloy from memory it was 7 years ago ? yes you have to make sure if you drill that you clear out any fillings before finalising the job .

  7. #7
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    Quote Originally Posted by Sunny43.5 View Post
    Alloy from memory it was 7 years ago ? yes you have to make sure if you drill that you clear out any fillings before finalising the job .
    I guess if I mark it with a marker, drill two holes, fit two screws, remove screws then pipe, I can vacuum it out then. and realign with marking pen marks.

  8. #8
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    Sounds like the best way or if you are lucky you could use some self tapping screws which will just make their own hole with no filings .

  9. #9
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    Try a new spring clip from VW first.

    If it pops off still, replace the pipe.

    Also, always lubricate the rubber seal with silicone spray, to prevent damage to the seal itself when installing. It also makes it easier to re-fit, as well as well, sealing it better.
    '07 Transporter 1.9 TDI
    '01 Beetle 2.0

  10. #10
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    It's the actual intercooler female pipe I'll have to put a screw though. So hard to get too. Waiting for a mate with longer drill extension. Can't wait till tuesday for VW dealers in Canberra to open to tell me they don't have it in stock anyway.

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