Intercooler Hose: Replacement Every 2000km?

Hello!

Today, or rather, last night, it happened again. This is now the third charge air hose, from the turbocharger to the steel pipe that leads to the intercooler, that has burst. Again, after only about 2000 km . This time, it was a flexible charge air hose from an Audi 100, 2.5 TDI, which 'only' cost 50€. Unfortunately, it tore in a place where I can't repair it. Apparently, it wasn't designed for the 1.45 bar pressure and 100K above ambient temperature . This junk can't withstand anything .



Rainer's shop offers connector pieces, but I need a hose that is made entirely of these connector pieces, making it highly flexible. Does anyone know where I might be able to find something like that? Or, does Rainer offer such a product upon request?

Best regards, Nebelwerfer.

Hello,
Perhaps you should try using Samco or similar silicone hoses. They definitely hold up much better than the TDI hoses!

Greetings.
Reuselkopp.

It's happening again. The other day on the A2 highway in the variable speed section, another one broke down. This time, I fear the engine sustained damage, as it happened under full load at 3200 RPM. I immediately took my foot off the accelerator, but the GRA (presumably a speed limiter or similar system) was still active in the background and tried to maintain the speed of 145 km/h for about 1 second.

Maybe you should try Samco or similar silicone hoses. They definitely hold up much better than the TDI hoses!

Do you perhaps know where I can get them? The selection at Rainer's shop is very limited .

Hm.. maybe take a look here http://www.sandtler.de/katalogangebote/samco/samco_index.htm.

There is a (silicone hose with a stainless steel wire insert for maximum flexibility), but it's also not exactly cheap .

Edit... the S-hose actually has two different widths. It's thin at the top and thick at the bottom .

Hi,
You can usually find Samco hoses at any retailer that offers tuning parts for 1.8T VAG engines. D&W also carries them... or just do a Google search! You can also find these hoses on eBay. They're not exactly cheap (there are alternatives), but they are definitely durable. On 1.8T engines, the pressure can reach up to 2 bar overboost. If the hoses are constantly bursting and flying around, it's definitely not a cheap problem to fix.

Nebelwerfer_TDI wrote:

It's happening again. The day before yesterday, on the A2 in the alternating section, another one was damaged. This time, I fear the charger was damaged, as it happened under full load at 3200 1/min. Of course, I immediately took my foot off the pedal, but in the background, the GRA (presumably a traction control system) was still active and tried to maintain the speed of 145 km/h for about 1 second.

Hi,

In your signature, you mention 1.1 bar, but you write 1.45 bar above. Even with 1.45 bar, it's baffling to me why so many hoses can fail with what seems like "so little" pressure.
Do you perhaps need to install them with some tension due to the "special charger," or do they experience a lot of movement?

Thanks for your replies, I'll check out Sandtler.

@ulf:

In your signature, there's something about 1.1 bar,

This refers to my 1.6-liter swirl chamber TD in (Pöl) 35i. The TDI (in the row below) is running at 1.45 bar.

but even at 1.45, it's baffling to me why so many hoses can fail with seemingly so little pressure.


The hoses are also mechanically stressed by tension. In the 3B model, the engine is mounted longitudinally, and (thanks to the flexible mounting ), it is always slightly lifted from the front axle when starting. This puts stress on the hose. In addition, there are approximately 100 kPa due to the outside temperature, and the pressure; I assume that the turbocharger can have up to 1.5 bar, as I have two intercoolers in series.

Nebelwerfer_TDI wrote:

This refers to my 1.6-liter swirl chamber TD in (Pöl) 35i. The TDI (below) runs at 1.45 bar.

Oops

Quote:

In addition, there will be an extra 100K due to the outside temperature.

"Most chargers do this (more or less) at around 1.5 bar - in fact, even more often. So the hoses should be able to withstand that pressure."

Quote:

However, I assume that the charger could also be supplying 1.5 amps, as I have two lithium batteries connected in series.

If that's enough, including the pressure losses in all the pipes up to the lambda sensor... I'd personally guess closer to 1.55 to 1.6 bar.

Today, it was number 5's turn .
I still need to buy a few more to have in reserve, before I go to Styria this weekend .

'Is there any way to install ARL hoses? - They are designed to withstand a constant pressure of 1.7 bar.'

Unfortunately, I've already reached that point. The problem is that it's always the hose immediately after the charger that bursts, and it's the one that's subjected to the most thermal stress. Sadly, there's not much space there, otherwise I would have already taken something from ARL and adapted it.

Hi,

Do you perhaps have severe pressure surges that you can't detect because you don't have a 250 kPa boost pressure sensor?
"Because it's never normal to have that happen with only 1.45 bar of pressure. Either the hose is too short, or the boost pressure is far too high, or the hose is much too hot (consider installing a heat shield)."

Best regards, Rainer.

No, not really; the pressure spikes (measured with a pressure sensor and gauge) reach approximately 1.6 bar, which translates to about 1.7 bar directly at the turbocharger, considering the two pressure relief valves in between. The last relief valve burst because, when tightening the hose clamp, it slipped too far over the intermediate piece (a 30-degree steel bend) and was therefore under tension on one side.

or the hose is much too hot (should a shielding plate be installed?).


Damit könntest du garnicht mal so falsch liegen - bisher sind ALLE Schläuche auf der Rückseite (zum Abgasgahäuse des Laders), oder nach rechts, wenn man davor steht (Krümmer, Adapterplatte) geplatzt. Villeicht hilft es wirklich, wenn ich mir ein Alublech zurechtbiege, und dazwischenhänge Werd mir, wenn ich heimkomm mal das Material der geplatzten Schläuche ansehen. Wenns zu heiß war, dann müßte man das anhand des brüchigen Gummis sehen. Danke Thank you for the tip!


EDIT: Okay, I just ordered a 135° and a 45° silicone hose bend from Sandtler. Sorry, Rainer, you didn't have them .

Once a support ring is in place (like the one that comes with the original hose), it should also hold up to the movements of the motor.

Thank you for your tips and suggestions!

One more question: What shape are the cracks? Are they longitudinal and diagonal, or are they along the edge?

Most often, the failures are radial cracks. However, the one that failed on me on the A2 highway in the transition zone also had an axial tear (which I attribute to the escaping pressurized air). This type of damage indicates mechanical stress, which is caused by the influence of heat and boost pressure.

By the way: Rainer was right in his assumption - the rubber is indeed brittle in the area of the damaged spot, likely due to heat exposure.

A bulge typically indicates mechanical overload, not excessive internal pressure.
However, such a hose is not homogeneous but fiber-reinforced. Perhaps it's a bit too focused on pressure.
The thing about the temperature is particularly intense .