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Old 11th May 2014, 21:09   #1
Arctic
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Default Intercooler Pipe Mod (diesel)

As most if not all the diesel R75 owners know our intercooler hoses/pipe can and will suffer over time with wear, this can come in differing guises, main hose from intercooler to turbo boost sensor through to EGR can also become porous, thus leaking the black oily deposits we see on them, they can also split and we then have to replace them at great cost, that is if you can find one for sale new.

I have for quite a while now been trying to think of something else we maybe able to use so I stated looking at BMW intercooler pipes which are mostly alloy, i bought several different ones earlier this year to see which if any could be adapted to the R75 diesel.

I also at the same time had to take in to account that my diesel R75 incorporates the turbocharger boost temperature sensor, and at the same time trying to look at the R75 which doe's not include the sensor.

I found a BMW one with a sensor already fitted into the alloy pipe which turned out to be the same size as the R75 sensor so that was a bit of luck, today after a few months of having these pipes I managed to get round to modifying one of the pipes the results are below.

These were the first to arrive the non sensor pipes in March Fig 1
1

The two sensor ones arrived later in March but I only took photo's of them recently Fig 2
2

Photo of the sensors close up the small R75 and the one in the BMW alloy pipe Fig 3
3

We will now move onto fitting the modified pipe/hose first you need to take the engine cover off, and unplug the lead to the turbocharger boost temperature sensor Fig 4/5
4

5

Next step in to loosen the jubilee clip holding the hose to the EGR Fig 6
6

Now loosen the jubilee clip in the intercooler bend Fig 7
7

Remove the whole section of pipe/hose including the sensor you can use this to copy the shape of the alloy pipe you will need for the modification below you will see I had already cut the pipe to the length I would need Fig8
8


After having our Sunday dinner I went back to fitting the pipe and it's adjoining hoses, which the EGR end was the one I took off originally, I have also now added the original sensor switch from my car into the BMW alloy pipe Fig 9
9

The only hose I have had to add, and cut down in size was from a Free Lander intercooler hose I had this is the part that fits to the bend as here in Fig 10
10

Make sure you get all the angles right then tighten up the jubilee clips Fig11
11


Reconnect the wiring plug, and replace the header tank which is best to drop out of the way when fitting the pipe/hoses, refit the engine cover and you have a new intercooler pipe which will not split, go porous or rub and chaff on the other parts of the engine and will not be in danger of getting burnt/melted from the FBH exhaust down pipe. Fig 12/13
12

13

The assorted pipes I purchased for the job, both sensor and non sensor cheers Arctic. Fig14/15 :thumbsup:
14

15
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Old 11th May 2014, 21:16   #2
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Good stuff Steve, and worth looking into, a new intercooler pipe I bought from Rimmers was £51 last year.
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Old 11th May 2014, 21:22   #3
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Well done Steve, looks a good job! Any links to the actual pieces of pipe, as I for one will probably buy the wrong ones!
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Old 11th May 2014, 21:33   #4
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brilliant mod!!!
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Old 11th May 2014, 21:33   #5
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I will still try to do what we was talking about on nano so this might be a good start for further development. How they works? Any changes?
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Old 11th May 2014, 21:35   #6
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Quote:
Originally Posted by Heddycdt View Post
Good stuff Steve, and worth looking into, a new intercooler pipe I bought from Rimmers was £51 last year.
Quote:
Originally Posted by Mark2000cc View Post
Well done Steve, looks a good job! Any links to the actual pieces of pipe, as I for one will probably buy the wrong ones!
Hi Les/Mark
yes I too checked out the price of the hoses on Rimmers late last year which prompted me into looking at something different, I will post up the ones I bought once I have had chance to see if the non sensor one is going to fit as there could be a few other that can be adapted, bearing in mind that these were bought on spec hoping that they would fit and as luck as it the sensor one as with a little bit of cutting and filing.
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Old 11th May 2014, 21:38   #7
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Thanks Steve, luckily mine is the sensor one so hopefully relatively simple, great find though and could save a lot of trouble in the future.
Just out of interest, was the total price for the bits less than buying a new oem intercooler hose?
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Old 11th May 2014, 21:40   #8
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I will still try to do what we was talking about on nano so this might be a good start for further development. How they works? Any changes?
Hi Piotr
Yes please do as I doubt these will be found in a good quantity and once the news gets out the sellers will up the price of that I am sure see you Wednesday bit more pick up I think but that could be the placebo effect but at least I will not have to worry about the pipe becoming porous or splitting while I am driving down the motorway
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Old 11th May 2014, 21:45   #9
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Originally Posted by Mark2000cc View Post
Thanks Steve, luckily mine is the sensor one so hopefully relatively simple, great find though and could save a lot of trouble in the future.
Just out of interest, was the total price for the bits less than buying a new oem intercooler hose?

Hi Mark.
I will have to brake it down as remember I have bought several to find out which is the best, but I would wait a little as I am in talks with someone about alloy pipes as of yet still in early stages.
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Old 11th May 2014, 22:06   #10
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Ok mate, look forward to future updates, mines not urgent so I don't mind waiting if you can maybe get something sorted. Much rather have a shiny alloy one than a silicone one anyway.
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