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Angus_Beef

Member Since: 30 Apr 2015
Location: Oslo
Posts: 434

2015 Defender 110 Puma 2.2 SW Corris Grey

Intercooler hose failure - 41,000 miles

Hi all, longtime lurker here... finally (!) have a story to share

So we usually spend some summertime in Norway and drive up from Switzerland. My preferred method is to drive overnight on Friday to Kiel and take the Keil-Oslo ferry to Oslo. 1000km overnight through Germany is peaceful- nearly no traffic, nice and cool temps and I can just cruise along while swambo sleeps.

My truck is LHD and I’m nearly deaf in my right ear. swambo wakes up and asks me if it is “very windy.” No, I said. Then I hear it. A rush of air. Must be pretty loud if it can be heard in the cabin of a defender going 80 miles per hour.

It’s 03:35 and we are 500km from Kiel when it goes into limp home mode. REALLY not optimal on unlimited sections of autobahn and soon we hit morning traffic...

Using the BAS IID tool I reset the mass air code and changed to the 122 tune. Not gonna work. 150 tune was better, but still not going to make it. On the 170 tune I could watch the Manifold Absolute Pressure and keeping it below 2.0 bar stave off the MIL/Limp. This means short shifting under 2000 and letting it pull from 1000 in almost every gear. The BAS 170 was good for this.

We made the final 500km by drafting lorries at 80-90kph and using their very slow hill performance as a safety measure. On the last 500km driving this way our consumption was 7.8L/100km (!!!)

When we got to the ferry checkin it was 9am and I called Peter at BAS and he was able to ship me silicone hoses that morning, which are scheduled to arrive today!

I just found the culprit. The hose from turbo to intercooler was rubbing against one of the three bolts that holds the air box in place....

Click image to enlarge

Click image to enlarge Roaming around 🇳🇴🇨🇭

4th Aug 2020 10:21am

Scotm

Member Since: 28 Feb 2014
Location: Aberdeenshire
Posts: 637

2012 Defender 110 Puma 2.2 SW Orkney Grey

Does yours have the bracket on the alternator to keep this hose clear of these bolts and steering joint?

I would be fitting silicon hoses with those remaps!

4th Aug 2020 10:46am

Angus_Beef

Member Since: 30 Apr 2015
Location: Oslo
Posts: 434

Well, the steering gear is on the other side of the truck, but no - there was no bracket on the alternator to hold the hose (this surprised me as i thought they all had it). Given the flat spot that is worn on the bolt, it appears the hose has been rubbinh on it quite a long time, probably since new Roaming around 🇳🇴🇨🇭

4th Aug 2020 10:56am

Scotm

Member Since: 28 Feb 2014
Location: Aberdeenshire
Posts: 637

Of course you are LHD!

4th Aug 2020 10:58am

DG123

Member Since: 29 Aug 2015
Location: North West
Posts: 133

2012 Defender 110 Puma 2.2 XS CSW Orkney Grey

Self amalgamating tape is your friend. It's what the LR assist used on mine to get me mobile again after the intercooler hose split whilst waiting for a replacement.

There are definitely some strange hose/loom routings used by Land Rover. On my D2 the power steering hose was cunningly placed to wear through out of sight on a random mounting bolt

2012 110 XS SW Orkney Grey
2003 D2 Td5 Black [SOLD]

4th Aug 2020 12:20pm

Co1

Member Since: 19 Aug 2018
Location: North Yorkshire
Posts: 3610

I used duct tape when mine went to keep me mobile. Was fine.

4th Aug 2020 12:53pm

tookaphotoof

Member Since: 18 Mar 2013
Location: dordrecht
Posts: 1279

2013 Defender 130 Puma 2.2 HCPU Santorini Black

Same here. Driving British cars learnt me duct tape and tie wraps will always get me home. 😂

4th Aug 2020 3:45pm

Angus_Beef

Member Since: 30 Apr 2015
Location: Oslo
Posts: 434

Quick update

Fitting the two of the three BAS silicone hoses was a piece of cake. They went on surprisingly easy. I bought from Pete the stainless hose clamp kit rather than reuse the factory clamps. Took it for a quick drive to get it hot and then tightened up the clamps just a tad. Sofar, all is well.

The long tube on the Right side of the car does need the bracket to the alternator I think. Not sure why my 2015 doesnt have that, but I will order one.

Thanks to the forum for all the great information over the years- it certainly made this process much less painful.

Cheers,
Dave Roaming around 🇳🇴🇨🇭

5th Aug 2020 1:26pm

LR90XS2011

Member Since: 05 Apr 2011
Location: bickenhill
Posts: 3612

2011 Defender 90 Puma 2.4 XS CSW Galway Green

only the day before yesterday I found my steering column was rubbing on my turbo to intercooler hose, mine is a 2.4 and it is not holed yet, have ordered a new hose and the alternator bracket designed for the 2.2 which others on the forum have told me also fits a 2.4.

Just need a free day to get it fitted, in the mean time a bit of string is holding the hose clear. DEFENDER 90 TDCI XS,

I hope everyone is well and your land rovers make you happy

17th Aug 2022 7:30pm

LR90XS2011

Member Since: 05 Apr 2011
Location: bickenhill
Posts: 3612

replaced it today, removing the air box to make space was the worst bit of the job, never used the bracket as the new hose is some way away from the steering linkage, will keep an eye on it thought. DEFENDER 90 TDCI XS,

I hope everyone is well and your land rovers make you happy

28th Aug 2022 8:40pm

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