DIY: 1.8T Charge Pipe Fix - VW Forum :: Volkswagen Forum
MK4 Discussion area for the new fourth generation Golf IV, 337, R32, 20th and Jetta IV produced from 1998 to 2004.5 including Cabrio models.

 
LinkBack Thread Tools Display Modes
post #1 of 15 (permalink) Old 12-23-2012, 12:46 PM Thread Starter
MK4 & MK5 Owner
Points: 39,983, Level: 100 Points: 39,983, Level: 100 Points: 39,983, Level: 100
Activity: 83% Activity: 83% Activity: 83%
 
_FUBAR_'s Avatar
 
Join Date: Oct 2009
Location: Pittsburghish
Posts: 8,352
Garage
so most of us with the 1.8t will be plagued by mysterious boost leak or boost surging. the biggest culprit is the charge pipe to the s hose with the c clip connection. over time the o-ring will fall apart and let boost leak by. this causes boost fluctions and leaks. a cheap fix to this is to buy 3 t-bolt clamps, silicone hose and a joiner.
what you need:
2.25in. x 3in. alum. or stainless joiner $10
2.25in. x 3in. silicone coupler $8
3 t-bolt clamps $10


tools needed.
10mm socket
flathead screwdriver
Dremel with cutoff disks

now you need to remove the charge pipe, s-pipe, and pancake pipe. start by removing the silicone hose from the charge pipe and DV.

remove the clamps and set aside.

now remove the smaller silicone hose from the charge pipe.

now unbutton the heatshield wrap.

move it to the side and loosen the hose clamp from the charge pipe.

remove the wrap and slide the hose clamp down and out of the way.

next using the 10mm socket unbolt the 2 10mm bolts holding the charge pipe clamps.


there are 2 more down the backside of the charge pipe that need to be removed as well.

charge pipe should be free.

now to start on the bottom side.
you will need to jack up the vehicle and remove the passenger side wheel.
reach up and loosen the clamp on the top of the pancake pipe.


now find the 10mm nut holding the pancake pipe to the frame.

remove it.

now find the 2 hose clamps holding the pancake pipe to the intercooler.

loosen them and you should be able to pull out the pancake pipe.

you should be able to see the s hose.

now go back up top to the charge pipe. remove it from the silicone hose to the turbo.


pull out the charge pipe and s hose.


here you can see the charge pipe to s hose connection.

use the flathead to pry of the clip.


MK4 & MK5 Owner.

Last edited by _FUBAR_; 12-23-2012 at 06:57 PM.
_FUBAR_ is offline  
Sponsored Links
Advertisement
 
post #2 of 15 (permalink) Old 12-23-2012, 12:46 PM Thread Starter
MK4 & MK5 Owner
Points: 39,983, Level: 100 Points: 39,983, Level: 100 Points: 39,983, Level: 100
Activity: 83% Activity: 83% Activity: 83%
 
_FUBAR_'s Avatar
 
Join Date: Oct 2009
Location: Pittsburghish
Posts: 8,352
Garage
pull them apart. you can see how the connection works using the o-ring. also notice the s hose has a metal ring around it.

this is why its faulty. torn o-ring.

clean off all the hoses, clamps, and charge pipe. this makes the job a lot cleaner.

laying out the parts.

now to modify the oem charge pipe and s hose.
cut the charge pipe just above where it starts to flare.

now cut the end of the pipe like so.

now you can bend and fold the cut section back and it will form a lip to prevent the hose from slipping off.

now for the s hose. carefully cut the metal end off the silicone hose.

cut through

pry the metal off. this will let you slip the end on your joiner.

shove the joiner in as far as it will go.

throw on your clamp.

now push on the silicone coupler.

add your clamp.

now the charge pipe and the s hose

join them together and clamp.

now you can reinstall the pancake pipe. then the charge pipe. you might have to adjust the s hose a little to get it to slip on the pancake pipe. I had to trim the end of the s hose a little.

do to the joiner being 3in. long it adds a little more length than the eom overall length was. 2.5in. joiner would probably work much better. just make sure the s hose does not pinch too much. reinstall all the charge pipe hold downs, charge pipe hoses and hose clamps. check for leaks.

MK4 & MK5 Owner.

Last edited by _FUBAR_; 12-23-2012 at 06:58 PM.
_FUBAR_ is offline  
post #3 of 15 (permalink) Old 12-23-2012, 06:51 PM Thread Starter
MK4 & MK5 Owner
Points: 39,983, Level: 100 Points: 39,983, Level: 100 Points: 39,983, Level: 100
Activity: 83% Activity: 83% Activity: 83%
 
_FUBAR_'s Avatar
 
Join Date: Oct 2009
Location: Pittsburghish
Posts: 8,352
Garage
done.

MK4 & MK5 Owner.
_FUBAR_ is offline  
post #4 of 15 (permalink) Old 12-23-2012, 07:41 PM
Junior Member
Points: 1,226, Level: 19 Points: 1,226, Level: 19 Points: 1,226, Level: 19
Activity: 1% Activity: 1% Activity: 1%
 
dallas257's Avatar
 
Join Date: Jul 2012
Location: Ft Campbell KY
Posts: 143
Send a message via Skype™ to dallas257
Ive been watching this all day for the final post! Good stuff Im going to have to take a look at mine and see if the o-ring is broken or not, I suspect it is. Did you just pick the silicon hose up at auto zone?


To view links or images in signatures your post count must be 5 or greater. You currently have 0 posts.
dallas257 is offline  
post #5 of 15 (permalink) Old 12-23-2012, 07:47 PM
Moderator
Points: 17,979, Level: 85 Points: 17,979, Level: 85 Points: 17,979, Level: 85
Activity: 50% Activity: 50% Activity: 50%
 
Shameless's Avatar
 
Join Date: Sep 2011
Location: Saint Paul, MN.
Posts: 4,465
Garage
fucking awesome write up

looks like your turbo is blowing oil all over that hose though.


To view links or images in signatures your post count must be 5 or greater. You currently have 0 posts.

Quote:
speed without looks is as useful as a girl without tits
Shameless is offline  
post #6 of 15 (permalink) Old 12-23-2012, 07:50 PM Thread Starter
MK4 & MK5 Owner
Points: 39,983, Level: 100 Points: 39,983, Level: 100 Points: 39,983, Level: 100
Activity: 83% Activity: 83% Activity: 83%
 
_FUBAR_'s Avatar
 
Join Date: Oct 2009
Location: Pittsburghish
Posts: 8,352
Garage
i ordered everything off ebay from different vendors.

yeah the turbo is leaking oil...i think. it might be pvc related however. still have to look into it more.

MK4 & MK5 Owner.
_FUBAR_ is offline  
post #7 of 15 (permalink) Old 12-24-2012, 03:25 PM
Moderator
Points: 17,979, Level: 85 Points: 17,979, Level: 85 Points: 17,979, Level: 85
Activity: 50% Activity: 50% Activity: 50%
 
Shameless's Avatar
 
Join Date: Sep 2011
Location: Saint Paul, MN.
Posts: 4,465
Garage
Could just be the seal too. That damn hose hasn't been taken off since it was put on by VW.


To view links or images in signatures your post count must be 5 or greater. You currently have 0 posts.

Quote:
speed without looks is as useful as a girl without tits
Shameless is offline  
post #8 of 15 (permalink) Old 12-24-2012, 08:49 PM Thread Starter
MK4 & MK5 Owner
Points: 39,983, Level: 100 Points: 39,983, Level: 100 Points: 39,983, Level: 100
Activity: 83% Activity: 83% Activity: 83%
 
_FUBAR_'s Avatar
 
Join Date: Oct 2009
Location: Pittsburghish
Posts: 8,352
Garage
ive had it off when i did the timing belt.

MK4 & MK5 Owner.
_FUBAR_ is offline  
post #9 of 15 (permalink) Old 12-24-2012, 11:07 PM
Posting Elite
Points: 7,803, Level: 59 Points: 7,803, Level: 59 Points: 7,803, Level: 59
Activity: 9% Activity: 9% Activity: 9%
 
Join Date: Dec 2009
Posts: 981
The oil is normal for the PVC if you don't have a catch can. If the turbo was blowing oil it would be pretty nasty and it would be smoking pretty good

New Official FB Page:
To view links or images in signatures your post count must be 5 or greater. You currently have 0 posts.


PM me or Email
To view links or images in signatures your post count must be 5 or greater. You currently have 0 posts.
for Custom Retrofit BiXenon Headlights


To view links or images in signatures your post count must be 5 or greater. You currently have 0 posts.
rodgertherabit is offline  
post #10 of 15 (permalink) Old 12-28-2012, 09:16 AM
Premium Member
Points: 10,660, Level: 68 Points: 10,660, Level: 68 Points: 10,660, Level: 68
Activity: 7% Activity: 7% Activity: 7%
 
05GTI1.8T's Avatar
 
Join Date: Aug 2009
Location: arlington heights, il
Posts: 1,454
Send a message via AIM to 05GTI1.8T
Every once in a while I blow blue smoke I think I need to look into that I'm suspecting my intercooler needs to be cleaned since I've nedver done it yet.. but I'm waiting on it caz I'm goin fmic just haven't gotten it yet

Awesome writeup fubar

[SIGPIC][/SIGPIC]

PM Me about VWF stickers

~Brian
05GTI1.8T - Under Construction
ASE Certified Technican
Quote:
vw's run on hopes and dreams bro.
05GTI1.8T is offline  
post #11 of 15 (permalink) Old 12-28-2012, 12:46 PM
Moderator
Points: 17,979, Level: 85 Points: 17,979, Level: 85 Points: 17,979, Level: 85
Activity: 50% Activity: 50% Activity: 50%
 
Shameless's Avatar
 
Join Date: Sep 2011
Location: Saint Paul, MN.
Posts: 4,465
Garage
The stock intake on these cars is pretty stout looking at this DIY.


To view links or images in signatures your post count must be 5 or greater. You currently have 0 posts.

Quote:
speed without looks is as useful as a girl without tits
Shameless is offline  
post #12 of 15 (permalink) Old 12-29-2012, 07:11 PM
Posting Elite
Points: 7,803, Level: 59 Points: 7,803, Level: 59 Points: 7,803, Level: 59
Activity: 9% Activity: 9% Activity: 9%
 
Join Date: Dec 2009
Posts: 981
The intake is really small. The inter cooler piping is 2in throughout.

New Official FB Page:
To view links or images in signatures your post count must be 5 or greater. You currently have 0 posts.


PM me or Email
To view links or images in signatures your post count must be 5 or greater. You currently have 0 posts.
for Custom Retrofit BiXenon Headlights


To view links or images in signatures your post count must be 5 or greater. You currently have 0 posts.
rodgertherabit is offline  
post #13 of 15 (permalink) Old 12-30-2012, 09:06 AM Thread Starter
MK4 & MK5 Owner
Points: 39,983, Level: 100 Points: 39,983, Level: 100 Points: 39,983, Level: 100
Activity: 83% Activity: 83% Activity: 83%
 
_FUBAR_'s Avatar
 
Join Date: Oct 2009
Location: Pittsburghish
Posts: 8,352
Garage
this solved my boost fluctuating issues. also im holding boost alot better.

MK4 & MK5 Owner.
_FUBAR_ is offline  
post #14 of 15 (permalink) Old 06-13-2015, 01:42 PM
Member
Points: 654, Level: 13 Points: 654, Level: 13 Points: 654, Level: 13
Activity: 80% Activity: 80% Activity: 80%
 
airjordanGTI's Avatar
 
Join Date: Nov 2014
Posts: 41
Garage
Quote:
Originally Posted by _FUBAR_ View Post
this solved my boost fluctuating issues. also im holding boost alot better.
awe all the pics are broken
airjordanGTI is offline  
post #15 of 15 (permalink) Old 06-13-2015, 11:21 PM
Member
Points: 48, Level: 1 Points: 48, Level: 1 Points: 48, Level: 1
Activity: 75% Activity: 75% Activity: 75%
 
Join Date: Jun 2015
Posts: 6
Book marking
EuroChris is offline  
Sponsored Links
Advertisement
 
Reply

  VW Forum :: Volkswagen Forum > Volkswagen Models > MK4

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the VW Forum :: Volkswagen Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.




Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Slow to charge michlowrider General Volkswagen Discussion 2 12-11-2009 10:03 PM
Get a charge michlowrider General Volkswagen Discussion 1 11-08-2009 04:05 PM
Oil in the charge pipes 109 LUVR Corrado 6 09-28-2004 02:08 AM
Charge! smoove1011 MK2 2 01-24-2004 03:32 AM
Turbo Charge or Super Charge big dub MK4 18 09-06-2003 02:09 AM

Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome