OEM charge pipe questions

[Blk_Rocco]

Search rendered no accurate results.


I recently acquired an 05 bhw TDI. Malone stage.

Driving today, seemed like the turbo was louder, lots of air noise, sounded like a substantial boost leak. Broke out VCDS and measure actual vs requested boost... It differed by about .8 bar then I got the codes P0299 and P010 when testing.

I inspected the charge pipes and noticed the one directly off the turbo is quite loose, not disconnected and the surrounding area was damp from oil blowby I assume.

Question.
1. If I'm seeing damp spots around charge pipe connections...there's a leak right?
2. How loose are these OEM connections typically?
3. These are O-ring sealed correct? Is there a kit out there to replace them all in our cars?

Thank you!!

 

[oilhammer]

Pull the hose off and look closely at the tabs on the aluminum collar that snaps into the turbo. If the tab is worn down enough, it will have a hole there, and that's a path for charge air to push breather oil out and make a mess. It also means the tube's snap fit is not as tight as it should be. A new o-ring won't help, you need a new hose.

This is sadly kind of a common issue with that type of connection. It was so bad on BEW Golfs and Jettas at the intake flap, that someone made a bracket for them to help hold the hose secure. I wish something could be made for all these type connections but it would not have the attachment bolts to use like the intake flap has.

 

[Blk_Rocco]

Ok... Well sounds like I need to purchase the expensive hose from somewhere.

Thanks for the answers... Hopefully that the only reason for my massive boost leak, I see no other obvious ones.

 

[Scubanero]

I had an O ring disappear once, presumably blown out. I have also had success with a lower priced hose than the OEM version. The aftermarket version with plastic hubs and no silencer baffle has lasted me for several years so far. It was about $60 CAD at the time.

 

[Blk_Rocco]

@Scubanero, good to know.. where did you get yours from.. I don't really feel like spending $300 on this pipe as I'm planning for a future FMIC.

 

[Scubanero]

ebay. It was a few (maybe more than a few) years ago. There are a bunch of cheap ones available, The first one I tried gave it up after a month or so. Look for one with composite end fittings.
Oilhammer is right though. Take a look and see what the problem is. You may just need to tune up the little tabs that catch the spring clip.

 

[CantWrite]

Another option @Mozambiquer is currently parting out a wagon and may have a good charge pipe.

the updated o-rings are green vs black from the factory.

I have read where others grabbed boost hose clamps from NAPA and added those, but not sure how well they worked.

 

[Windex]

Self tapper screws. Just make sure to remove and clean out any shavings