Lower intercooler pipe mod - how to.

first-things-first · 4th August 2015, 21:01

Many thanks to Shawn for the original idea, sizings and getting me on the right track here - http://www.the75andztclub.co.uk/foru...=183346&page=8.

This is for those of you that would like to fit silicone intercooler pipes to replace the lower intercooler hose. I also have a FBH, which Shawn did not.

Wullie480 has a replacement upper intercooler hose on this thread - http://ww.the75andztclub.co.uk/forum...d.php?t=183775.

After replacing mine, it might feel a little better and more responsive. Although the placebo I also fitted at the same time as the snake oil mod has helped.

I thought the original rubber hose would be as swollen as the upper (EGR) hose, but due to not getting a lot of oil coating, it was quite OK. It's now my backup, just in case.

The style police will notice I used blue and black hoses. Quelle horreur!

The reason - the 60 degree hose was not available in black that I could find.

Now, I differ from Shawn's build as I could not fit 2 90 degree silicone hoses without probably deforming the hoses and maybe putting pressure on the plastic lower intercooler outlet.

So I purchased :

1 x 60 degree hose 51mm - http://www.ebay.co.uk/itm/201353561874
1 x 90 degree hose 51mm (choose colour and size) - http://www.ebay.co.uk/itm/310793012250
1 x stainless 50mm tubing - http://www.ebay.co.uk/itm/251812391744
5 x 45 - 60mm hose clips - http://www.ebay.co.uk/itm/311364232785

You only need 2 clips if you re-use the 2 originals as I did. No harm in getting more, just in case.

The 90 degree hose goes on at the engine end. You need to cut off around 9 cm of stainless pipe to use as the joiner between the 2 hoses.

image26.jpg

The 60 degree hose will need to be cut as the leg is around 15cm (taken from the mid point of the pipe) and needs to be nearer 10cm at the inner bend as can be seen here :

image22.jpg

I used a very sharp craft knife to cut the pipe by hand. Cuts quite well, once you have the first cut made through the wall of the hose. Then you just cut through the wall, bit by bit.

There is an angle to the whole assembly as per below.

The 2 side by side :

image15.jpg

One on top the other - you can just see the slightly different angle at the bends.

image18.jpg

Another angle.

image19.jpg

I used a little vaseline to make them slide easier.

I first tightened a hose clip to the lower 60 degree pipe with the stainless joiner inserted and then tried a test fit.

The gap to the FBH exhaust is tight, but there is a little gap. The original was almost touching and does not look like it melted.

image3.jpg

I wanted a good fit, so the inter cooler outlet pipe was not under strain too much.

The whole assembly fitted well, the black silicone pipe needed a little tension to fit snugly and squarely on the shoulder of the metal pipe.

To fit the hose clip on the lower inter cooler hose, I had to take off the corner bumper cover and lay underneath the car. You can do most of it by touch and then checking visually.

The almost final result after checking test fit - missing a hose clip.

image1.jpg

No issues so far. Boosts well. No hoses popping. The hoses are NOT fluro silicone lined, but as I said earlier not much oil in there.

Besides it cost just over £20 to do.

Cheers

Andrew

Disclaimer:
You are responsible for any work or modifications carried out on your car and you undertake any such work at your own risk.
The 75 and ZT Owners Club nor the original author of this How-To can be held liable for anything that may happen as a result of you following this How-To.

ceedy · 15th August 2015, 11:14

Excellent now I have a use for my Spare 60 degree Bend

and it will match my blue top hoses

C.

Jakg · 13th September 2015, 10:29

Thanks for the how-to - just done this.

I used the flouro lined elbows from SFS bought along side the upper hose (about £40).

Theirs are quite a bit shorter so you need a much longer joiner - i.e. the full 250mm I think. This was a pain as I'd already cut mine to 90mm! So I ended up getting a 300mm one on eBay. I also gave the joiner a quick coat of paint to make it less blingy.

I've had a lot of boost hoses come off so I spent a little extra on genuine Jubilee clips - http://www.ebay.co.uk/itm/3512464527...%3AMEBIDX%3AIT - £0.99 each.

Terrible picture:

4th August 2015, 21:01	#1
first-things-first Posted a thing or two MG ZT Join Date: Jul 2014 Location: Hornchurch Posts: 1,255 Thanks: 176 Thanked 352 Times in 272 Posts	Lower intercooler pipe mod - how to. Many thanks to Shawn for the original idea, sizings and getting me on the right track here - http://www.the75andztclub.co.uk/foru...=183346&page=8. This is for those of you that would like to fit silicone intercooler pipes to replace the lower intercooler hose. I also have a FBH, which Shawn did not. Wullie480 has a replacement upper intercooler hose on this thread - http://ww.the75andztclub.co.uk/forum...d.php?t=183775. After replacing mine, it might feel a little better and more responsive. Although the placebo I also fitted at the same time as the snake oil mod has helped. I thought the original rubber hose would be as swollen as the upper (EGR) hose, but due to not getting a lot of oil coating, it was quite OK. It's now my backup, just in case. The style police will notice I used blue and black hoses. Quelle horreur! The reason - the 60 degree hose was not available in black that I could find. Now, I differ from Shawn's build as I could not fit 2 90 degree silicone hoses without probably deforming the hoses and maybe putting pressure on the plastic lower intercooler outlet. So I purchased : 1 x 60 degree hose 51mm - http://www.ebay.co.uk/itm/201353561874 1 x 90 degree hose 51mm (choose colour and size) - http://www.ebay.co.uk/itm/310793012250 1 x stainless 50mm tubing - http://www.ebay.co.uk/itm/251812391744 5 x 45 - 60mm hose clips - http://www.ebay.co.uk/itm/311364232785 You only need 2 clips if you re-use the 2 originals as I did. No harm in getting more, just in case. The 90 degree hose goes on at the engine end. You need to cut off around 9 cm of stainless pipe to use as the joiner between the 2 hoses. image26.jpg The 60 degree hose will need to be cut as the leg is around 15cm (taken from the mid point of the pipe) and needs to be nearer 10cm at the inner bend as can be seen here : image22.jpg I used a very sharp craft knife to cut the pipe by hand. Cuts quite well, once you have the first cut made through the wall of the hose. Then you just cut through the wall, bit by bit. There is an angle to the whole assembly as per below. The 2 side by side : image15.jpg One on top the other - you can just see the slightly different angle at the bends. image18.jpg Another angle. image19.jpg I used a little vaseline to make them slide easier. I first tightened a hose clip to the lower 60 degree pipe with the stainless joiner inserted and then tried a test fit. The gap to the FBH exhaust is tight, but there is a little gap. The original was almost touching and does not look like it melted. image3.jpg I wanted a good fit, so the inter cooler outlet pipe was not under strain too much. The whole assembly fitted well, the black silicone pipe needed a little tension to fit snugly and squarely on the shoulder of the metal pipe. To fit the hose clip on the lower inter cooler hose, I had to take off the corner bumper cover and lay underneath the car. You can do most of it by touch and then checking visually. The almost final result after checking test fit - missing a hose clip. image1.jpg No issues so far. Boosts well. No hoses popping. The hoses are NOT fluro silicone lined, but as I said earlier not much oil in there. Besides it cost just over £20 to do. Cheers Andrew Disclaimer: You are responsible for any work or modifications carried out on your car and you undertake any such work at your own risk. The 75 and ZT Owners Club nor the original author of this How-To can be held liable for anything that may happen as a result of you following this How-To. Last edited by Dragrad; 4th August 2015 at 22:04.. Reason: Thumbnails enlarged and Disclaimer added

15th August 2015, 11:14	#2
ceedy This is my second home All Trophy Blue ,ZT260#50 , ZT CDTI Auto, ZR105+ and 1.8T Firefrost spoiling the Set . Join Date: Nov 2006 Location: Nr Sherborne But in Somerset.. Posts: 6,077 Thanks: 916 Thanked 1,214 Times in 768 Posts	Excellent now I have a use for my Spare 60 degree Bend and it will match my blue top hoses C. __________________ The Three Bloo's Wifey's Zr105, MY CDTI & 260 #50 and Number One sons 1.8T in Firefrost When I were a lad Zero to 142 in 10.25 secs at the Pod on my Blown Norton. 210 Kart Champ in 70's

13th September 2015, 10:29	#3
Jakg This is my second home N/A Join Date: Feb 2010 Location: Suffolk Posts: 6,867 Thanks: 0 Thanked 397 Times in 302 Posts	Thanks for the how-to - just done this. I used the flouro lined elbows from SFS bought along side the upper hose (about £40). Theirs are quite a bit shorter so you need a much longer joiner - i.e. the full 250mm I think. This was a pain as I'd already cut mine to 90mm! So I ended up getting a 300mm one on eBay. I also gave the joiner a quick coat of paint to make it less blingy. I've had a lot of boost hoses come off so I spent a little extra on genuine Jubilee clips - http://www.ebay.co.uk/itm/3512464527...%3AMEBIDX%3AIT - £0.99 each. Terrible picture: