Author Topic: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating  (Read 10996 times)

Offline ams_sxi

  • Not said much yet
  • **
  • Posts: 63
1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
« on: 16 September 2014, 12:02 »
Thought i'd give the intercooler a clean.
Took it all off ok, put it back together but the lower pipe on the bottom of the intercooler does not seat properly, it fits ok but when i take it for a drive it becomes loose and looks like it is going to pop off
 
I am quite sure it was on ok before i took it off. But it is not going back on properly.
 
It connects via a clip on to a red coupler.
 
Any ideas?
 
I dont think nothing is wrong with the clip, could be the coupler?
 
Should i buy a new one of these
 
http://www.ebay.co.uk/itm/VW-Golf-Mk4-Audi-A3-Mk1-1-9-TDi-130-BHP-ASZ-Turbo-Intercooler-Pipe-/221536438978?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item339499cac2

Offline scarr89

  • I live here
  • *****
  • Posts: 3,223
  • Mk4 Golf, DERV FTW!
Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
« Reply #1 on: 16 September 2014, 16:26 »
These f**king connectors are a pain to fit. You really have to give them a good shove to get seated, and then put the C clip in place making sure the flanges are past the clip.

I wouldn't just buy a new one of those, there is a popular SMIC upgrade for maybe £100 if you are thinking about upgrading/modding.

I'll try and find the link.

Offline leigh_harty

  • I live here
  • *****
  • Posts: 1,463
  • Audi AGU
Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
« Reply #2 on: 16 September 2014, 18:52 »
Ive just had this problem if you look in the non diesel section  :whistle:

The uprated one doesn't use that clip system so you need to spend a further ~£15 more on clamps and silicone joiners
Dont lose your dinosaur!

Offline thai-wronghorse

  • Serious forum addict
  • *
  • Posts: 7,325
  • mk1 Seat Leon FR TDI
Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
« Reply #3 on: 16 September 2014, 21:04 »
I found my short red coupler to the intercooler had become slightly curved over the years which then let oil drip from it. I flipped it 180° and cleaned it all up and it hasn't leaked since.

Offline ams_sxi

  • Not said much yet
  • **
  • Posts: 63
Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
« Reply #4 on: 17 September 2014, 09:37 »
So just bought a new one from my TPS, it was £48!

It kept popping off and losing boost and smoking loads so had to buy a new one.
I am not sure how to fit it, any ideas?
Don't want to pull the old one off and then have problems trying to fit the new one...


Offline leigh_harty

  • I live here
  • *****
  • Posts: 1,463
  • Audi AGU
Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
« Reply #5 on: 17 September 2014, 11:32 »
1st remove your bumper, watch this video for the locations of fasteners

https://www.youtube.com/watch?v=rfRCaJHrj8c

then both outlets have a clip that wraps round, use a screwdriver to ease it off, when refitting make sure the connectors are pushed in good and proper! I refitted my leaking one yesterday and it popped off and took the part of the pancake pipe that holds on the clips...
Dont lose your dinosaur!

Offline thai-wronghorse

  • Serious forum addict
  • *
  • Posts: 7,325
  • mk1 Seat Leon FR TDI
Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
« Reply #6 on: 17 September 2014, 12:30 »
I just removed my arch liner for access rather than taking the bumper off. It was a good excuse to clean out the compost heap in the arches as well.

Offline ams_sxi

  • Not said much yet
  • **
  • Posts: 63
Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
« Reply #7 on: 22 September 2014, 20:25 »
so fitted the new connector and new clips on the car today. Under pressure it popped off, soo annoying.

I don't know why it keeps popping off, should i change it for a silicon pipe and jubilee clips?

Offline Rhyso

  • Global Moderator
  • Sir Postalot
  • *****
  • Posts: 26,729
Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
« Reply #8 on: 22 September 2014, 20:40 »
Stupid question but did the new pipe come with the o-ring?

Equally you may find the end the pipe is going into might be worn  :sad:

Offline old_n07

  • I live here
  • *****
  • Posts: 728
Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
« Reply #9 on: 23 September 2014, 16:07 »
Have you got the clip the right way round and the ends of it seated in the locking lugs on the housing?
Quote from: mikemk4golf
Hey you're a moderator, I want a serious answer not someone who takes the piss!

Grammar is the difference between Helping your Uncle jack off a horse and Helping your Uncle Jack off a horse.

Not so standard Gt TDi
Cluster Mods FAQ | Miles to Empty Guide