Intercooler Hoses from HELL!!
 

I needed to replace some hoses on Helga, my turbo volvo wagon. I ordered a silicone cooling hose kit from IPD in Portland but "cheaped out" and bought an intercooler hose kit from another place. I'm not sure if the problem was the "other guy" hoses or if I just hit on a fabulous streak of personal incompetence...

I didn't want to do the work inside the shop, I've got the shop pretty full right now. So I put a set of ramps just outside and drove the car up. After a reasonable cool-down period, I set to work. I really should have paid more attention to the vehicle's placement as I was directly under the edge of the roof and rain was promised. Tear down was a piece of cake. Probably had 20 or 25 minutes into that. All the intercooler hoses were easy to remove and one of them had a bulged soft spot with a bit split it in it. Probably the problem with boost.

The silicone coolant lines were a piece of cake. Fit perfect, went on easily. Everything I've come to expect from IPD. Now the "other guy's" silicone intercooler hoses. I spent 4.5 hours putting them on. I swear they are too small. I fought, shoved, pushed, and did every cheater trick I know. THe rain started pouring down, and at the edge of the roof directly over the bumper, it was basically a waterfall. I had to work in that until I could get everything back together enough to start the car. Couldn't get the lower hose on with all the water in my face, so fired the car up without it and moved a few feet further into the shop. Hose went on easily after that.

It's all good. No looks, good boost. But my hands hurt so bad that clearly housework is out of the question for a couple of days - LOL!

So - are intercooler hoses supposed to be that hard to put on? Or is this brand just indeed a little too tight? They are further secured with clamps. Or, heaven forbid, am I just displaying a bit of incompetence?

angela

I usually use a little vaseline on them to help slide them on.

Dish detergent.

Did the vaseline - that's the only reason I was able to shove them on at all. At one point, I had a metal tube held between my knees (sitting on the shop chair - aka 5 gallon bucket) and both hand wrestling the hoses on. Even at that point, those two particular hoses took more than half an hour... And that was with the tube out of the car. The rest had to be installed on the car. Good thing the engine bay is big. Sheesh!

Came home and told the kids it was "Fend for yourself Dinner"because I am NOT cooking - LOL!

angela

Before anyone else says it, this thread is a thing of beauty.:)

Best thing to use. Vaseline can cause it to come off if not secured properly.

I used to have a Volvo and loved IPD's stuff!

Correct!!!! Ding ding!! Dish detergent is the best thing to use.

I had a Volvo Turbo wagon that cooked the turbo. That was the tightest fit, two person, nasty job I ever did. I hated that car afterward.

I looked at that, and if I ever have to replace the turbo, I'm dropping the drivetrain. Or paying someone else - LOL!

Rest of the car is pretty easy to work on. A bit busy on the front, but the engine bay is big enough to get ahold of things. Though evidently, dishwashing liquid will become my new best friend if I ever have to take those darn things off again!

I'll get that Palmolive so I don't get dishpan hands - LOL!

angela

The worst part was doing it twice. The first rebuild was FUBAR'd and I had to pull it and wait for another unit.....