Passat Intercooler Hose. Symptoms and fix

overseasSoul said:

My Passat 2012 TDI SEL (NMS) emitted a soft "bang" from the engine compartment on normal driving and I had to limp home recently. I thought it would be a huge deal and that it was major damage. With a bit of reading around on this forum, I discovered that one of the causes of a soft "bang" is a blown intercooler hose (between the turbo and the intercooler). I hooked up VCDS and was able to show a big difference between turbo boost requested and delivered on the advanced measuring blocks. So I confidently put the car on ramps, took off the undercover and yes- there it was, a blown hose, like a radiator hose, with about a 6 inch 90 degree angle. I looked up the part from VW - about $270!
I saw a video on Youtube https://www.youtube.com/watch?v=uvr8c4896Mc that showed how to replace the hose, so I bought a section of matching radiator hose from Advanced AutoParts, cut it to size and fitted it moderately well. Problem solved, but I wasn't completely happy using this part.
The good news is I read this forum a bit more and discovered that I still had a valid VW settlement warranty on my Passat for another year, and that it covered the entire fuel system, turbo, intercooler etc. So I took it into the dealer, and with great good luck and feeling a bit foolish, they replaced the part with the correct VW part under warranty, removing my "temporary repair". Thanks VW!

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