Intercooler Pipe Modification by Arctic


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Arctic
(Trader)
As most if not all the diesel R75 owners know our intercooler hoses/pipe can and will suffer over time with wear, this can come in differing guises, main hose from intercooler to turbo boost sensor through to EGR (Exhaust Gas Recirculation Valve) can also become porous, thus leaking the black oily deposits we see on them, they can also split and we then have to replace them at great cost, that is if you can find one for sale new ? I have for quite a while now been trying to think of something else we maybe able to use so I stated looking at BMW intercooler pipes which are mostly alloy, i bought several different ones earlier this year to see which if any could be adapted to the R75 diesel.

I also at the same time had to take in to account that my diesel R75 incorporates the turbocharger boost temperature sensor, and at the same time trying to look at the R75 which doe's not include the sensor.

I found the BMW one with a sensor already fitted into the alloy pipe which turned out to be the same size as the R75 sensor so that was a bit of luck, today after a few months of having these pipes I managed to get round to modifying one of the pipes the results are below.

These were the first to arrive the non sensor pipes in March Fig 1
Image1

The two sensor ones arrived later in March but I only took photo's of them recently Fig 2
Image2

Photo of the sensors close up the small R75 and the one in the BMW alloy pipe Fig 3
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We will now move onto fitting the modified pipe/hose first you need to take the engine cover off, and unplug the lead to the turbocharger boost temperature sensor Fig 4/5
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Image5

Next step in to loosen the jubilee clip holding the hose to the EGR Fig 6
Image6

Now loosen the jubilee clip in the intercooler bend Fig 7
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Remove the whole section of pipe/hose including the sensor you can use this to copy the shape of the alloy pipe you will need for the modification below you will see I had already cut the pipe to the length I would need Fig 8
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After having our Sunday dinner I went back to fitting the pipe and it's adjoining hoses, which the EGR end was the one I took off originally, I have also now added the original sensor switch from my car into the BMW alloy pipe Fig 9
Image9

The only hose I have had to add, and cut down in size was from a Free Lander intercooler hose I had this is the part that fits to the bend as here in Fig 10
Image10

Make sure you get all the angles right then tighten up the jubilee clips Fig 11
Image11

Reconnect the wiring plug, and replace the header tank which is best to drop out of the way when fitting the pipe/hoses, refit the engine cover and you have a new intercooler pipe which will not split, go porous or rub and chaff on the other parts of the engine and will not be in danger of getting burnt/melted from the FBH (Fuel burning heater.) exhaust down pipe. Fig 12/13
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The assorted pipes I purchased for the job, both sensor and non sensor cheers Arctic. Fig14/15 :thumbsup:
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Image15

Posted 12 May 2014, 14:50 #1 

User avatar
squire
:clap: Hi Steve,
That looks an excellent mod. Approximately, what would the cost be?
Regards,
Martyn
Martyn

Posted 12 May 2014, 17:46 #2 

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Trebor
Yes nice one Steve !
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Planning is an unnatural process, much better to just get on with things, that way failure comes as a complete surprise instead of being preceeded by a period of worry and doubt

Posted 12 May 2014, 21:27 #3 

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Arctic
(Trader)
I was over Brum today and did quite a lot of motorway driving and main A roads etc the pick up on the car since I added the alloy pipe is so much better, I am guessing it is because the pipe is not expanding and contracting like a rubber hose would, therefore losing some boost impressed :thumbsup:

Posted 15 May 2014, 01:15 #4 

User avatar
ceedy
Steve, can you give a linky to the metal pipe type...

I might as well use this mod in conjunction with my plan to pop in a later ( OBD2 compatible) ECU (Engine Control Unit) in my dizzle, and to do this properly and avoid any error codes I need to put in the top sensor.

As I will have to get the hose adapter/sensor from somewhere, I thought as an option i might go Beemer.. :-D

cheers

Chris
Got one for Me , Then one for her, and now a big one for me again, All BLOO! Well saves on the touch up paint, Now Number one son's Spoilt it all by getting a Firefrost 1.8T

Posted 15 May 2014, 09:27 #5 

User avatar
Arctic
(Trader)
ceedy wrote:Steve, can you give a linky to the metal pipe type...

I might as well use this mod in conjunction with my plan to pop in a later ( OBD2 compatible) ECU in my dizzle, and to do this properly and avoid any error codes I need to put in the top sensor.

As I will have to get the hose adapter/sensor from somewhere, I thought as an option i might go Beemer.. :-D

cheers

Chris


Hi Chris
They are BMW I bought four in all to trace which one would be best for my car, which as the boost sensor, and that came from a 2003 BMW E46 320d Intercooler Pipe M47N cost £27 minimum that's average price but at least I know I will not have to change the pipe once it starts to deteriorating, at a cost of £50 a time either for OEM or silicone and the boost is so much better. cheers Arctic

Posted 25 May 2014, 00:39 #6 


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