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ParabolicSwivel

Member Since: 13 Nov 2013
Location: Hertfordshire
Posts: 42

Intercooler hose went POP

Afternoon.

Yesterday evening, while driving at about 65 on a motorway, I heard a loud and dramatic pop, hiss and whistle and found I had no power above 2000 rpm. Almost exactly 1 week after the warranty ran out! After crawling a mile or so to the next junction at about 45mph and then waiting for the nice AA man to arrive we found that the turbo hose had blown off the intercooler.

After re-connecting the hose and clearing the error codes it's running like a dream again.

Have to thank the very kind driver of a lovely black 110 USW who took pity on me and bought me a cup of tea. Really perked me up and reminded me what a nice bunch Land Rover drivers are in general.

Question is what caused this?

The hose had recently been replaced as per the recall, so it was the new hose with the bracket on the alternator. The end of the pipe looked quite roughly cut and the doesn't seem to be much slack in the hose length-wise.

So is it a case of the Nottingham LR dealer not knowing how to use a jubilee clip or cutting the pipe too short with their blunt scissors, or what? Not exactly the first thing they've messed up. Do I take it back there and ask them to put a longer pipe on there or just wait to see if it comes off again? Actually I think I'd rather just do it myself.

Is there any other reason the pipe would blow off like that?

Also, the was a small amount of oil running down the intercooler onto the chassis and onto the floor (stopped now). Should I worry about that or is that expected in the circumstances?

Was glad it didn't do it on my outbound journey at 4am...

3rd Apr 2015 3:48pm

YOLO110

Member Since: 14 Feb 2015
Location: Perth Oz and Stansted UK
Posts: 1633

Time to fit a proper aftermarket silicon hose now!

YOLO... You Only Live Once...

3rd Apr 2015 8:00pm

Egghead

Member Since: 25 Nov 2012
Location: Surrey
Posts: 255

2007 Defender 110 Puma 2.4 XS CSW Java Black

Any pics? Has the hose ballooned in any way along the length or did the end of the hose strip under the jubilee clip so the end just blew off?

If you want to fit the best, I think the Samco XDB Turbo Hoses fit the bill and they have a special thick cuff on the ends to prevent the hose sliding underneath the clip. They look pretty good too!

I can only dream of the Samcos though and had to fit some slightly cheaper silicone hoses. They can be fitted fairly easily without having to remove anything except maybe the fan cowl for a short while. Have your best patience hat on when you try pushing the new hoses onto the pipe

3rd Apr 2015 11:55pm

ParabolicSwivel

Member Since: 13 Nov 2013
Location: Hertfordshire
Posts: 42

No pics as it was getting dark... Didn't see any bulges or anything - the pipe still with jub clip on was just hanging loose. No damage visible on the pipe or hose. Strange sort of jubilee clip I haven't seen before though - there was a separate bit of metal going about 30mm round the circumference of the hose stuck to the hose by little teeth, with the clip going round that.

The error codes were:
P2263 Turbocharger charging system malfunction (twice)
P0101 Mass or volume air flow circuit outside specified range

Still running ok now, so as a precaution I will look at some silicone hoses. The Samco ones look rather nice (but pricey) though can only see ones for the 2.4 listed - are they the same for the 2.2? And do you know if they still fit ok with the new recall bracket/spacer thing on the alternator?

4th Apr 2015 8:04pm

Sarawakboy

Member Since: 05 Apr 2015
Location: Sarawak
Posts: 5

2013 Defender 110 Puma 2.2 DCPU Auto Blenheim Silver

I had the exact same issue with the turbo hose and my car was in the garage for 3 months because they couldn't figure it out that the hose has blown a hole ( at 9000km). And the replacement hose blow off the turbo on my way home. Genius. So my question is what's the "recall" on the Turbo hose? My replacement hose was completely different from the Factory Hose ( replacement hose is completely made of Rubber with stainless steel rings and the Factory Hose is a 3 part hose with a Plastic middle section).

5th Apr 2015 6:45am

noworries4x4

Member Since: 24 Dec 2010
Location: Newton Abbot Devon
Posts: 1195

My 2.4 and 2.2 are always doing it bloody things, now I am out of warranty I am waiting for BAS to get some more 5ply silicone ones back in stock and I will be fitting them asap with proper clips. Now there is another argument ?? which clips to use, some say very thin stainless ones so they have good bite and a small high pressure contact area or wide bolt style clamp, large surface area and can be done up very tight. Against some advice I am going to try the larger ones this time I have had enough of burning my hands putting turbo hoses back on, considering a smear of glue as well had to do that years ago on an Isuzu I had the hoses just would not stay on after the pressures were wound up. If everything is under control you are not going fast enough.

Every Day 16 MY Discovery 4 Commercial Workshop and Escort Vehicle
Weekends 07MY L322 TDV8 Vogue SE
Series 1 80" 3ltr 6cyl with overdrive
No Worries 4X4

5th Apr 2015 9:51am

Supacat

Member Since: 16 Oct 2012
Location: West Yorkshire
Posts: 11018

2013 Defender 110 Puma 2.2 XS DCPU Keswick Green

Are the tubes the hoses connect to fitted with beads? If not this could be the best answer, irrespective of which type of hose you fit.

6th Apr 2015 4:06pm

ParabolicSwivel

Member Since: 13 Nov 2013
Location: Hertfordshire
Posts: 42

Sarawakboy, as far as I know the recall is to prevent the hose from chafing on the alternator. My replacement hose was as you describe but there is also an oddlooking bracket bolted to the alternator that I'm pretty sure wasn't there before.

Supacat, the pipe entering the the intercooler seemed to be plastic, with small ridges rather than a large bead like your pic.

Interesting that it's not unknown. Maybe not entirely the dealer's fault that it popped off then - more like poor design of the intercooler inlet or something. I wonder if glueing a bigger bead onto the pipe might be an option, along with a second jubilee clip. Wonder if I could fit 3 clips on there.

Do silicon hoses grip better anyway though? Have to say that being a bit of a traditionalist I've never use silicon hoses before, but if needs must...

7th Apr 2015 8:38pm

shaggydog

Member Since: 12 Aug 2012
Location: Kent
Posts: 3346

1991 Defender 110 200 Tdi USW Arles Blue

Bit of advice for when fitting silicone hoses.

The interiors of a silicone hose are very shiny and smooth which is great for the passage of gasses and fluids but not for grip.

Grab some emery paper and "rough up" the area under the clamp on the inside of the hose. This will allow the hose to have more grip on the pipe and stop it from slipping off. Don't go mad, it just needs to be enough to take the shine off.

I did it on my hoses and (although a 200Tdi is not the same as TDCI) mine have shown no signs of movement or leakage and are still tightly gripped in place

Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197

Self confessed mileage hunter

7th Apr 2015 9:01pm

pannawonica

Member Since: 21 Nov 2010
Location: Clackline Western Australia
Posts: 568

After a fail too proceed experience with TD5 Disco, I replaced my Puma 110 with silicone pipes from Alive in warranty. They dealer didn't evan notice! Thing is when I took them off they appeared cheap and thin, exactly the same as the coolant hoses when I changed too a 82c thermostat. My question is when would be a good time to change all hoses out?

8th Apr 2015 1:24am

Supacat

Member Since: 16 Oct 2012
Location: West Yorkshire
Posts: 11018

ParabolicSwivel wrote:
Sarawakboy, as far as I know the recall is to prevent the hose from chafing on the alternator.

I think it's actually the Steering Column Lower Shaft and specifically the universal joints that the hose can rest on.

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8th Apr 2015 6:31am

YOLO110

Member Since: 14 Feb 2015
Location: Perth Oz and Stansted UK
Posts: 1633

The OEM hose looks rubbish!

Imagine how turbulent the airflow is with all those bumps in the hose! Do any peeps with silicone hoses note better drivability? YOLO... You Only Live Once...

8th Apr 2015 8:13am

Supacat

Member Since: 16 Oct 2012
Location: West Yorkshire
Posts: 11018

I haven't taken the hose off but from close inspection of the outside the bumps are entirely external and there just to provide some degree of protection.

8th Apr 2015 8:56am

jomara

Member Since: 26 Oct 2009
Location: Lanarkshire
Posts: 1762

2014 Defender 110 Puma 2.2 XS CSW Santorini Black

The wire stops the hose ballooning under pressure, the effect on airflow would only become an issue on tuned engines where you're trying to push the maximum amount of air and fuel into the combustion chamber. 2014 110 2.2TDCi XS Station wagon
1971 Bowler Tomcat 88 4.2 V8 Auto
2022 110 250D XS

8th Apr 2015 8:59am

Sarawakboy

Member Since: 05 Apr 2015
Location: Sarawak
Posts: 5

This was the Original Factory Fitted Turbo Hose for my Puma 2.2 , you can see that the middle section is of a Plastic Construction. I would have prefer this to the current

Replacement Hose which seems to balloon grotesquely whenever i floor the throttle. So i guess this may be a reliability issue pretty soon.

8th Apr 2015 3:40pm

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