Boost hose from EGR to intercooler

[dieselnewbie]

Hi, hope someone can help. I've a PD130 engined Galaxy, I need a new boost hose that goes from the solid metal pipe off the EGR valve and connects to the intercooler. I tried Ford but they wanted Ã,£170+!! Anyone now where I can get a cheaper one? I've tried ebay but no joy :-/

[insanitybeard]

Which part is actually broken? Looking at the parts diagram, the EGR to intercooler pipe is listed as a complete assembly (everything with the yellow triangle) or as individual parts (number 4 is the bit that goes into the EGR valve), it's always possible that Ford have superseded it and will now only sell you the job lot but Ford do at least list it as separate parts.

[dieselnewbie]

Thanks for the reply, looking at the diagram it looks to me if is no.3 hose I need, but mine is a different shape? My hose has two metal castings at either end (part no. 3M21 9C606), if that helps. One of the metal lugs has worn down probably when someone attempted to refit it at some point, loosing a lot of turbo boost :-/

[insanitybeard]

It won't be number 3 if it's coming off of the EGR valve, number 3 is the flexible section of hose that links the intercooler (offside connection) to the rigid aluminium pipe (number 2) that clamps onto the sump on the offside of the engine and then runs into the turbo.

[dieselnewbie]

That's the one! Sorry if I wasnt clear, should have taken a photo just dont know how to upload on here

[insanitybeard]

So when you said it was the EGR to intercooler pipe what you actually meant was the turbo to intercooler pipe......?  In that case then yes it is no. 3 on that diagram, the metal end of that pipe that connects to the intercooler is pictured below:

[attachimg=1]

On my '54 reg 130ps TDI, that hose only has a metal termination on the intercooler end, the end that connects to the rigid aluminium section of pipe is simply a push fit with a jubilee style clip. I presume you mean it's the metal locating lug visible in the above picture that's worn? That lug doesn't provide any kind of seal, it merely locates the pipe into the intercooler. The seal is actually provided by an 'X' section o-ring which sits in the groove also visible in the above picture (at least on my vehicle), are you sure it's not that that's defective? Is the spring clip that holds the pipe into the intercooler doing it's job properly?

At a glance, and without checking part numbers, this and this (which is cheaper but possibly not genuine) looks like the part to me, it's still expensive, but not 170 quid! Like mine it does have a metal termination at one end only though.

[dieselnewbie]

This is a pic of the hose. Hopefully :-/ . Thank you for your help matey, appreciated :-)

[dieselnewbie]

Not the same hose as you showed, this one is a the bottom of the engine, at the front left kinda underneath the alternator. Do apologise for poor info but I'll take a pic tomorrow of where it goes.

[insanitybeard]

We are talking about exactly the same pipe, just yours has a slightly different design to mine. In the picture I posted above you can see the alternator at the upper left, the hose in that picture (that I circled the intercooler end of in yellow) drops down and meets the rigid aluminium pipe which runs along the side of the sump (and secures to it via a bracket). Unlike my setup however, the hose you have has metal terminations on both ends. The hose I pictured in my above post is the same hose shown below meeting the aluminium pipe which runs along the side of the sump, though as you can see mine just secures to the aluminium pipe via a jubilee clip:

[attachimg=1]

[dieselnewbie]

That's it, any ideas why there are so many configurations for what is essentially the same part? Nightmare! Got a spare for Ã,£35, just hope it's the same!!

[dieselnewbie]

Typical luck, wrong part :-( . Anyone know where I can get one, have looked pretty much everywhere. I am loath to give Ford Ã,£175+!!

[Chrispb]

This looks like the one below in this old ebay post try ringing a VW dealer with the part number may be cheaper.

http://www.ebay.co.uk/itm/VW-SHARAN-ALHAMBRA-1-9TDI-ASZ-BTB-TURBO-INTERCOOLER-PRESSURE-HOSE-7M3-145-737-/400395502603

[dieselnewbie]

That is it, thanks Chris. I did try VW but because I mentioned Ford Galaxy, the guy lost interest. He might be a tad more helpful with a part number lol. Thanks again

[dieselnewbie]

The lugs on the pipe would appear to offer some sort of seal/mounting, as soon as the boost builds then the hose blows off. Some idiot had actually tried to use a cable tie around the metal pipe, oh my days!! One of the lugs is completely worn hence the blowing

[insanitybeard]

Thinking about it, although the raised lugs on the metal pipe termination don't actually form a seal, what they do infact do is provide something for the retaining spring clip to engage against- without them, like you say, the pipe is able to pop off.  Just as a side thought, is the spring clip that retains said pipe present and correct in the intercooler itself (i.e, the pipe's not coming off because the clip is missing or damaged)?

[dieselnewbie]

The springs are fine, one of the lugs is worn down completely so it will not locate in the metal pipe coming off the turbo. Thanks for the replies :-)

[insanitybeard]

No worries! Those lugs are fairly robust, I can't imagine them just wearing down even with ham-fisted fitting, they only locate in the plastic intercooler port so that wouldn't cause them to wear in itself, unless somebody has intentionally tried to grind it off, but as to why, I can see no reason.

Anyway, it's irrelevant- if it's busted then you need a new one. Have you managed to source? I managed to find somebody yesterday on in Germany selling what I believe was aftermarket ones for fifty odd quid plus postage but frustratingly I can't find the listings now, possibly they finished and will be relisted again in due course.

[dieselnewbie]

Found one on turbohortum.com for €93 delivered, from Turkey bizarrely

[Craig Bray]

Where is the boost pipe on a Mk2 1.8tdci? I have plugged my obd reader in and I'm getting a code for turbo charger / super charger under boost. Im going it's just worked it's easy loose and nothing more sinister.