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Replacing Boost Pipes from EGR to Intercooler

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Yet another question.

Pretty much all my boost pipes are leaking oil form the joints and I was planning on replacing them with the ASH pipes on ebay, as I have seen several people on here have done so.

Does anyone have a parts with of exactly what I will need, size coupler, pipes etc? My car is current as standard as they come.

Sorry for been a Noobie

  • Author

Anyone? I know the simple answer re sizes is go and measure.

However, the pipe to the egr won't budge so it looks as though I will have to cut it off when fitting the new pipes.

The oil coming from the pipes can be solved with this mod.

Once the stock pipes are cleaned then you'll have no more oily pipes. While you're at it you should clean the intercooler out as well, as this is where the oil gathers.

If you still want new pipes, the 90 degree pipe to EGR that you mentioned is held in with a clip on the EGR, just pull the metal wire you can see about 1cm in from the edge of the rubber pipe meets the metal, it will unclip and the rubber pipe will now pop out. Replacing it may be tricky due to the fact you'll need the metal collar which is attached to the rubber pipe.

The collars can be acquired from Forge....I have one :)

9994224E-6C42-4D3B-B541-262B0E262D55-242-00000008F7F54CDC_zpse75d35d3.jpg

  • Author

Thanks I had seen this mod but never really thought about doing it.

Are the pipe generally hard to come loose, as Ive pull on line to ni avail, and even priseing with a screwdriver it barely comes out.

What do you recommend to clean the intercooler? Carb cleaner? Planning on doing the egr at the same time too.

I plan to get new pipes as the last owner has screwed them together so they are not the most air tight of all things.

They pipes are held together by clips you can see the clip in my picture.

Carb cleaner to clean out the intercooler but I used petrol and it cleaned mine out well.

For the intercooler, any kind of detergent will do since it's only oil.

The EGR is a whole different ball game, it's oil mixed with soot from the EGR - expect lots of scrubbing. A 25 minute soak with Mr Muscle Oven Cleaner worked well for me. :happy:

As for the IC pipes, who screwed them together? do you mean jubilee clips or actual screws through the piping? :whew:

Edited by Ben90

  • Author

Corrected due to autospell..

"Are the pipe generally hard to come loose, as Ive pull on mine to no avail, and even prising with a screwdriver it barely comes out."

  • Author

That looks what I'm after Dan, don't suppose you can remember the measurements of what you ordered?

Heard about the egr, been trying to do it for a while, but can't remove due to stuck 90 pipe... Thanks for the advice re cleaning.

The pipes themselves are screwed together, even a whacking great one through the egr and 90 pipe.

Not the most elegant of mods have been done on this car....should see the pd160 attempt...

PICTURES :rofl:

The rubber pipe you mention was probably superglued to the EGR, if the screw story is anything to go by.

This raises a new concern, why did the prev. owner take such serious measures to keep the pipes together?

Edited by Ben90

  • Author

Yes sorry, will get some tomorrow.

I thought it might be something like that, hence my reluctance to prise too hard, break and have to wait for new pipes.

Hoping the reason is nothing serious and the prev owner just got carried away, as the 90pipe to plastic pipe connection comes apart very easily....once you've taken the screws out that is....

That's something special, never heard of that before. We'd like to see the pictures for 'educational' purposes :giggle:

All jokes aside, the pipes should come apart easily once unclipped, but due to the... originality of the previous owners... repairs, who knows what else could have been used to hold them together. I would probably replace all the pipes with stock ones again, maybe from another member on here or from a rear-ended scrapper. Then do the CCV mod I linked in my first post to sort your oil problems :happy: That would be the cheapest fix. Of course you can still go for the shiny pipes should you want to.

Edited by Ben90

  • Author

Will get you the educational material tomorrow. Need to take another for a completely different question.

How much would.I be looking at for stock parts? With the problems everyone seems to have, I figure I might as well spend a little more and prevent future issues. Plus ASH pipes don't seem too pricey.

Do you vent your CCV to atmosphere or catcher can?

I had a catch can for about 600 miles, it filled up too quickly for my liking, mostly with water. The catch can went out the window at that point and I just routed it to the floor, no problems :happy: The amount of oil that actually comes out is tiny, so don't worry about puddles etc. It's better out than in!

  • Author

Thanks Dan!

Looks like i am going to be busy, just got to clear the garage so i can get the car in, as i dont fancy leaving it without a bumper while the intercooler dries from its clean.

No worries mate, you will need the seals from your standard pipework though.

Let the cooler dry in front of a fire or something like that.

  • Author

I did think about the seals when i saw them, not as cheap as i had hoped, though I suppose they are machined parts...

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