150k mile turbo making good boost.

U

Un4tural

Member
Hi Guys,

I feel like i should've posted my car in project page at this point, so with my fresh clutch I was obviously giving it the beans and well the high pressure hose that goes from turbo to inter cooler escaped (Hi if you saw me on the A3 side stop/parking under the car) got under it slip hose back and tighten it down - now it seems hoses are going as it actually pulled the lip off above the clamp for the hose and slipped off the metal turbo bit.

Presumably i need one of these 6X0145828A - anyone done this work before by any chance? how feasible would be to buy some silicone hose to replace it with instead as surely that'd be a lot cheaper? - plus the hose stretch from metal section to inter cooler underneath the car? Luckily access isn't too bad even with my hulk hands.
 
Timmus had a set of custom hoses made up for his TDi 120 engine project and also had sets for sale. - https://www.a2oc.net/community/index.php?threads/tdi120-my-new-engine.32986/post-281763
Worth asking if individual hoses are also available

Fig 8.4 shows a set of green hoses - https://www.a2oc.net/community/index.php?threads/tdi120-my-new-engine.32986/post-281495

The process is quite involved (read not cheap) and starts with a special mandrel which mirrors the inside shape of the standard Audi hose. The new hose is then built up by hand, layer on layer of silicone and reinforcing mesh then finally 'cured'
The tricky bit is designing the mandrel so it can be removed from new hose.

Cheers Spike
 
Blimey - think i'll opt for the OEM hose will ask my mate as he might have a forming tool to shape the hose but that's definitely more involved than i can do at the moment other than buying the kit.

An excellent read and amazing job by Timmus though! I'll get an OEM replacement hose which should last a good while until i decide what i want to do as i'll have to strip the turbo at some point due to oil leak somewhere above it but for now i'll just patch it up and enjoy the car for a little while.

Edit - Ordered what looks like the right part - 6X0145828A with some jubilee clips hoping this is the pipe that is split as well - otherwise i'll need to go check the rest of plumbing as well. Should be here Tuesday will fit and hopefully carry on choo choo just as before.
 
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To update - that was the correct part fits fine (only one way though it seems - old hose had no problem going either way!) making better boost but i suspect inter cooler needs a check, there is a fair bit of breeze coming from where intercooler sits putting hand in under the indercooler towards front of car, don't think there is anything that would cause airflow there, downward or outward from that area.
 
Un4tural said:
To update - that was the correct part fits fine (only one way though it seems - old hose had no problem going either way!) making better boost but i suspect inter cooler needs a check, there is a fair bit of breeze coming from where intercooler sits putting hand in under the indercooler towards front of car, don't think there is anything that would cause airflow there, downward or outward from that area.
Click to expand...
Hi I'm interested to see if you found where the "breeze" was coming from?
I have a tdi90 with a "breeze" but can't pinpoint where.It almost feels like it's coming from the bottom of the air filter box.But I thought that would draw air in and not out?
 
O07JESTER said:
Hi I'm interested to see if you found where the "breeze" was coming from?
I have a tdi90 with a "breeze" but can't pinpoint where.It almost feels like it's coming from the bottom of the air filter box.But I thought that would draw air in and not out?
Click to expand...

Not gotten around to it yet - debating whether i want to go dig behind engine to find my oil leak or peel the bumper off and look for the boost leak.

Mine has damage on pumper right where intercooler is(a fair crack that is) so i am assuming it is intercooler. air box is somewhat next to it however there doesn't seem to be much flow around that when feeling around, i get a hefty breeze when jamming my hand in front of intercooler though though gap isn't large. Will go tackle it when weather is less wet.
 
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