Intercoller clamps

[GBall]

I am sure ya folks have gone over this before But How tight do I do the clamps from my turbo to the intake need to be? I am a little concerned that I might break them and don't want to be stuck in the drive way. So if I use a open wrench how muck do I crank on them suckers. I did crank on them some last night and I think I might of had a little leak cuz it feels like it had a little more poop this morning. Thank ya all

 

[Gary C]

Snug but not knuckle busting tight like a nut and a bolt tight.

BTW, in the morning hp is different than heat soaked hp. If I had to guess it would be a 10% difference in power. That is one of the beauty's of guages you can see the difference. I had mine clamps loosen up and saw on the guage that I lost 7lbs of boost.



Hope this helps.

 

[nps]

GBall,



If they've been loose you also want to be sure to check for and clean off any oil/grease around the coupling. Othewise they may blow off regardless of how tight they are.

 

[illflem]

I feel it's good idea for everyone to use a torque wrench at least once to get a feel for how tight the clamps are really supposed to be. Manual for a 12 valve recommends 72 inch/lbs. I know I would have never considered tightening that much until I used a torque wrench. It must work, mine have never come off and I have seen boost up to 40 psi.

 

[hammong]

40 INCH-pounds, or 40 FOOT-pounds? 40 in-lbs isn't very much torque at all. I'm pretty sure when I torqued mine down, I did it well into the ft. lbs range.



Greg

 

[illflem]

Whoops! typoed with my boost pressure. It is 72 inch/lbs (6 ft/lbs). Try it you will see it's plenty tight.

 

[15w40]

I noticed that my maximum boost was lower than usual and decided to test for air leaks. A 4" PVC cap, found at Home Depot, fit inside the hose that connects to the air filter. After drilling and fitting a quick connect for an air hose, I was set to go. I had thoughts of setting the pressure at 20 psi or higher but that hose got excited and grew to about twice its normal length with less than 7 psi. I had some concern that it might fail and left the pressure at 7 psi. I was surprised to find three different leaks from the hoses to the intercooler and intake horn. Tightening the clamps helped but didn't stop all the leaks. I removed the clamps and hoses, cleaned the fittings with naphtha and then used some RTV to glue the hoses back on. After tightening everything back up and waiting for the RTV to set, there were no leaks. A few weeks later I retested and it is still leak free.



Some food for thought; the 4" hose has a cross section area of 12. 57 square inches. If the boost pressure is 20 psi, the force trying to push the hose out from under the clamp is 251 pounds. At 30 psi boost, the force is 377 pounds pulling on that hose. I guess it's no wonder these clamps are having problems.

 

[Roger rodbolt]

15W40,

You're right on target although I've only siliconed the imperfections. Also check for rough casting on the aftercooler inlet/outlets. Take a piece of emery cloth to the connections (shoe shine style) you may be surprised how little contact the emery makes. If you have time, sand or strip the paint from the contact area of the hose connector tubes for extra insurance against hose slip/leaks. The stock rubber boots are billowed outward in the center which tends to shorten the hose length as it swells under boost. IMO they are not designed stay in place. Troublefree BOMB'ing requires attention to detail!

 

[cwsoules]

Inner Cooler Hose Blow Off

I have had my inner cooler hose blow off the turbocharger three times. The first was the worst when towing 10K up a settp grade on I40 at 40 mph in second there was a loud bang and a hiss and the power dropped. I finally went over the top in 1st at 20 mph. The hose had blown off completely.



The second and third time I was towing the same 5er up a steep hill when the hose partially blew off causing a loss of power. I then started to check the clamps before towing a heavy load and found that they are no longer tight. I then would tighten them.



I have just installed some Breeze constant torque clamps and have yet to test them. I have these clamps very tight too.



I do not have any gages to determine what sort of pressure my turbocharger is putting out. When I get the VB, TC etc mods I'll probably put them in.

 

[tschwab]

I have actually had a hole, blow in one of the intercooler hoses, replaced under warranty and it seems to be of thicker and better quality than the original, thinking about buying a 2nd one as a spare.

 

[EOliver]

I ran across this site for silicone hoses a while back. I just happened to save the link thinking I might get some pretty ones to spice up the engine compartment in my truck someday.



Silicone Hoses

More Silicone Hoses

 

[TowPro]

I had one of the hoses on my 98. 5 keep comming off. Somebody on this list (sorry, forgot your name, and lost all my old email) sent me 2 off his 99. Guess what, the 99 had a hose about 1/2"-1" longer, fit much better, more room for a clamp.



I used both of them and have not had any problems since!

Originally posted by GBall

I am sure ya folks have gone over this before But How tight do I do the clamps from my turbo to the intake need to be? I am a little concerned that I might break them and don't want to be stuck in the drive way. So if I use a open wrench how muck do I crank on them suckers. I did crank on them some last night and I think I might of had a little leak cuz it feels like it had a little more poop this morning. Thank ya all

 

[Bob Wagner]

Re: Re: Intercoller clamps

Originally posted by TowPro

I had one of the hoses on my 98. 5 keep comming off. Somebody on this list (sorry, forgot your name, and lost all my old email) sent me 2 off his 99.



[/QUOTE



TowPro it was <b>Rob Hanson</b> that sent you the hoses.



Rob will be helping me this weekend install a set of BD2's



Rob is always willing to help out

 

[TowPro]

Re: Re: Re: Intercoller clamps

Thats right, Rob! Then I sent his buddy a K&N airfilter, with a note telling him he should join TDR because of things like "pay it forward"!

Originally posted by Bob Wagner

Originally posted by TowPro

I had one of the hoses on my 98. 5 keep comming off. Somebody on this list (sorry, forgot your name, and lost all my old email) sent me 2 off his 99.



[/QUOTE



TowPro it was <b>Rob Hanson</b> that sent you the hoses.



Rob will be helping me this weekend install a set of BD2's



Rob is always willing to help out