2009 TDI lower coolant hose removal

evoblade · Jul 6, 2017

I'm sure this is going to be very simple, but at this point I have spent two frustrating evenings trying to get the lower coolant hose removed from the radiator. I removed the locking clip from the connection but the cottonpicker wont budge. I'm afraid I will break something. What is the trick here. I found a similar thread (http://forums.tdiclub.com/showthread.php?t=389383 ) that advises PB blaster. Is that a good idea? This damn thing wont budge!!!

evoblade · Jul 6, 2017

Picture of the removed clip: http://i.imgur.com/ZGa87zo.jpg

Picture of the clip: http://i.imgur.com/MAKR9NG.jpg

firehawk618 · Jul 8, 2017

Wiggle, pull, wiggle pull. Probably just really stuck on there.

No real tricks.

The PB blaster recommendation is for re installing the hose.

I personally use whatever I have laying around. WD40, dab of oil, trans fluid whatever. Just lube the o ring up with something and it goes on fairly easy.

evoblade · Jul 8, 2017

Its definitely a stubborn bastard. I'm trying to figure out how to put a comealong on it! I guess I'll go try again... spent about 4 frustrated evenings on this so far.

meerschm · Jul 9, 2017

I just pulled the hose from the adapter further up the line, past the hard plastic end part. there is a hose clamp that is easier to remove with the right cable operated hose clamp.

evoblade · Jul 9, 2017

That's probably what I'll do. I wasted enough time on this joker.

Ol'Rattler · Jul 10, 2017

PB Blaster is a bad idea. It might cause the hose to rot/swell over time and wouldn't gain you anything because it is formulated to free rusted fasteners.

Look at the tool on the right. it would probably be very useful to remove the hose.

https://www.amazon.com/Tool-Aid-13860-Hose-Removal/dp/B002YKIZBA

edge130 · Jul 10, 2017

I concur with the above referenced tool
I actually have a SnapOn radiator hose removal tool, it's shaped a little different
But basically the same principal.
Insert it between the hose and the male connector and run it around once.
It's very effective in removing hoses.

jetlagmech · Jul 11, 2017

When I did my TB last year I decided that hose was the hardest part of the entire TB job. I finally used large channel locks on it, lightly twist to break it free then wiggled it off. You have way more patience than I.... it took me only about a half hour to think 'screw it' and grab the channel locks.

If it don't go.....FORCE IT. If it breaks.......IT NEEDED REPLACED ANYWAY.

oilhammer · Jul 11, 2017

FWIW, I find carb spray works great on the plastic quick connect couplings many manufacturers use on the cooling system components.

The problem is, you cannot twist the connector, because there is an index tab on the neck. So you can only pull straight off. Too much wiggling and you can fatigue the neck itself, especially on the radiators.

But if you get the clip out, liberal dose of carb spray, then some wiggling with gentle tugs, more spray, maybe wait a few minutes, then come back to it, and it will eventually come off. My thinking is the two plastic bits weld themselves together over all the heat cycles, and you need a little solvent to get in there and free the two parts up.

I have used this method successfully for years.

firehawk618 · Jul 11, 2017

That's interesting. I would have been hesitant to use carb spray just for the fact that it can destroy some plastics and rubber.

I'm not saying it does it to any plastic and rubber but will most definitely do it to some.

Perhaps the combo on our cooling system isn't one of those that break down.

Ol'Rattler · Jul 13, 2017

Carb cleaner is some pretty safe stuff. Remember that a carb has O-rings and other non metal parts in it.

Removing the flange does seem like a waste of time. Unless it is leaking let it be and just remove the hose.

firehawk618 · Jul 13, 2017

Whoa, two members from the same town. I don't think in all my years on forums I've ever had someone else from Marysville.

Ol'Rattler · Jul 14, 2017

There are a few of us, actually. What kills me is folks that put their location as "Planet Earth" or something like that. It sure makes it tougher to help someone with a problem that might be location related.

As an aside, my 2006 BRM will be the last TDI I will ever buy. At least with it, you wouldn't have to mortgage your house like you might have to for the CR's with the ex$pensive problems they develop.

firehawk618 · Jul 15, 2017

Ol'Rattler said:
There are a few of us, actually. What kills me is folks that put their location as "Planet Earth" or something like that. It sure makes it tougher to help someone with a problem that might be location related.

As an aside, my 2006 BRM will be the last TDI I will ever buy. At least with it, you wouldn't have to mortgage your house like you might have to for the CR's with the ex$pensive problems they develop.

Ah yea that's a good point about vague locations.

I personally wouldn't hesitate to buy a CR if the price / condition were right.

I love the way they drive.

My daughter has a 10' Jetta DSG that's getting turned in soon.

I've been using it to upgrade my 06' to an extent.

firehawk618 · Jul 15, 2017

Speaking of which, and not trying to hijack too much but she's got a full set of wheels + damned near new tires that as long as there's something to swap on she would sell for a really good price.

evoblade · Jul 23, 2017

I got the rad hose removed from the 90 degree fitting pretty easily. Now I can't get the dang wire locking device back on! I'm guessing that won't be a big issue, but what do you guys think?

jetlagmech · Jul 23, 2017

You need to get the lock back on. Don't want the hose fitting to break free in the middle of a trip. usually its just figuring out orientation to slip it back on. Can't get it....Can't get it....Can't get it.....Take a break, when you come back it will just slip right in. Or better yet about the time you decide to ask for someone to help you it will just slip right on for them.

Glozuke · Mar 19, 2023

evoblade said:
Picture of the removed clip:

http://imgur.com/ZGa87zo

Picture of the clip:

http://imgur.com/MAKR9NG

Hey, is it absolutely necessary to remove this clip entirely off of fitting in order to remove the hose? Thx

Rx7145 · Mar 19, 2023

I’ve left the clip on and undid the hose clamp. Seems to work fine. I was afraid of a coolant leak because of an old oring leaking.

Steve Addy · Apr 1, 2023

Glozuke said:
Hey, is it absolutely necessary to remove this clip entirely off of fitting in order to remove the hose? Thx

It's not supposed to need to be completely removed but these metal clips are troublesome and get in your way when you have to wiggle these things apart. It's also hard to grab the plastic flange with the clip in place, hence why I often remove it completely.

I will admit these radiator hose attachment "improvements" are more annoying than what was there before with simple hose and clamps. Not sure why all the additional crap was necessary.

Steve

turbodieseldyke · Apr 1, 2023

Steve Addy said:
Not sure why all the additional crap was necessary.

It's harder to work on, and more expensive to produce. Makes no sense.

oilhammer · Apr 3, 2023

Makes perfect sense. It ISN'T more expensive to produce, and they are FAR easier to assemble, which makes the car less expensive to build yet again. Also, I really don't find them especially bad to deal with in most situations.

turbodieseldyke · Apr 3, 2023

It's not cheaper and easier than pushing/pulling the hose on/off a fixed outlet on the radiator.

Rx7145 · Apr 3, 2023

Oil hammer might be saying that on a production line, simply clicking them on would be slightly faster.

oilhammer · Apr 3, 2023

Having assembled (and disassembled) countless cars' cooling systems, I assure you, the quick couplers are many orders of magnitude faster to assemble. No tools required, even in tight access areas... they just push right on and snap in place. This is why ALL the manufacturers are using them.

And, in a lot of cases, they end up being a bit easier to disassemble, as the clip is easily removed completely, you do not have to fight with not only releasing the CT clamp, but sliding it up and off the hose connection, which often involves a bend in tight quarters, THEN you have to work the hose loose from the [usually plastic] fitting it has stuck on and doesn't want to easily release from just like the o-ring in the quick couplers.

Anyone who disagrees with me simply hasn't worked on many modern vehicles.

Steve Addy · Apr 3, 2023

Yes....when this stuff is all new it's really not a problem. It's only later after it's been cooked in place for a decade where it's a problem getting it undone.

Steve

oilhammer · Apr 3, 2023

Correct, which is of zero concern to the manufacturers. They make the cars easy to assemble. Fewer steps, faster ways to mount and connect things.

They've also had/have quick connect things for fuel lines, transmission/oil lines, A/C lines, in addition to coolant lines.

Those of us old enough and fortunate enough to have worked on Ford Aerostars loved those firewall HVAC connections!

2009 TDI lower coolant hose removal

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