DIY: 1.8T Charge Pipe Fix

[_FUBAR_]

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.

[_FUBAR_]

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.

[_FUBAR_]

done.

[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?

[Shameless]

fucking awesome write up

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

[_FUBAR_]

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.

[Shameless]

Could just be the seal too. That damn hose hasn't been taken off since it was put on by VW.

[_FUBAR_]

ive had it off when i did the timing belt.

[rodgertherabit]

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

[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

[Shameless]

The stock intake on these cars is pretty stout looking at this DIY.

[rodgertherabit]

The intake is really small. The inter cooler piping is 2in throughout.

[_FUBAR_]

this solved my boost fluctuating issues. also im holding boost alot better.