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Model specific boards => Golf mk4 => Golf mk4 TDI => Topic started by: ams_sxi on 16 September 2014, 12:02

Title: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
Post by: ams_sxi 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

Title: Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
Post by: scarr89 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.

Title: Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
Post by: leigh_harty 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

Title: Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
Post by: thai-wronghorse 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.

Title: Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
Post by: ams_sxi 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...

Title: Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
Post by: leigh_harty 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...

Title: Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
Post by: thai-wronghorse 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.

Title: Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
Post by: ams_sxi 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?

Title: Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
Post by: Rhyso 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:

Title: Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
Post by: old_n07 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?

Title: Re: 1.9 Tdi 130Bhp Intercooler Lower Pipe Not Seating
Post by: leigh_harty on 23 September 2014, 17:47

Quote from: old_n07 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?

This

it might just be a simple case of having the clip in the wrong position, Not sure if you can use silicone on a standard smic, you need to on the uprated ones though