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Thread: Defender Puma 2.2 intercooler hose to throttle body should be replaced

  1. #1
    Join Date
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    Defender Puma 2.2 intercooler hose to throttle body should be replaced

    Hi all, I have seen many threads where it recommends that the inter-cooler hoses should be replaces with silicone hoses, however many of the kits do not include the 90 degree hose that goes from the steel connecting pipe to the throttle body.
    The other day I had a whooshing noise occur on the way home and knew it was one of the inter-cooler hoses, the Defender went in to limp-home mode, luckily I have a Scan Gauge fitted so I could clear the error code while I drove the 80 km commute home. ( was not going to leave the Defender or the wife on the side of the road)
    The throttle body inlet hose had split, luckily Super Cheap actually keep them in stock, 50x63x127 mm 90 degree reducer hose.
    Silicone direct also sell them if are happy to wait.
    90 Degree Silicone Reducing Elbows
    Fitting the hose is an absolute pain....and I am a mechanic by trade....after some time complimenting engines on how wonderful their designs are in the way they can put so many rubber hoses on the back of the water pumps and make no room what so ever.
    The easy way is to unbolt the water pump and tie it up out of the way, loosen the hose clamp off the throttle body, then you have access to remove the steel inter-cooler pipe, cut the new silicone hose to length, loosely fit the smaller end to the pipe and refit into position using the inter-cooler hose to the steel pipe as a guide.
    Adjust the new hose to the correct angle so it can easily be fitted to the throttle body without kinking the hose, remove the pipe and new hose, then fit the smaller end hose clamp.
    Fit the pipe with the new hose to the throttle body and tighten the hose clamps.
    Refit the water pump and you are done.
    Can this job be done on the side of the road if you or a mate had a spare hose on a trip....yes if you move the water pump out of the way, and remove the lower cooling fan cowling, to make it easier to get to the water pump bolts, you will also need a 3/8 drive square drive or ratchet for the serpentine belt tension adjuster in your tool kit, apart from that no other special tools would be required, flat blade screw driver and a 10 mm ring spanner.

  2. #2
    Tombie Guest
    Kits do come with it..



  3. #3
    Join Date
    Jan 2015
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    Hi Ozrob,

    Long time lurker, first time poster here thought would add to your original post as i recently(last week) upgraded to a 170AB tune + BAS intercooler and BAS hose Kit and very happy with the results.

    I particularly wanted to share my experience changing the 90 degree Elbow (lot of sweat, blood and skin lost in the process) which will benefit fellow 2.2 Puma owners.

    I tried various ways but the one that worked for me did not require me to remove the water pump.

    Here is what should work and can be done quiet quickly (mind you this took me a day to work out )

    1. Remove the metal pipe connecting the return intercooler hose to the elbow connected to the throttle body by removing 2 10ml bolts. (loosen and slide back the hose clamps from the elbow and one from the return hose connecting the metal pipe)

    2. Remove old Elbow (Once the pipe is removed you will have easy access to remove the elbow)

    3. lightly grease the lip of the throttle body to help install the new hose along with clamp. please make sure the clamp is tight enough to secure hose in place, but not torque it up yet as you will need to align with the metal pipe. (In my case I also used my right hand through coolant pipework to position and push up the elbow into place.

    4. lightly grease the lip of the metal pipe to be connected to the elbow.

    5. Reinstall the metal pipe (might have to align with right hand and jiggle/push fit into elbow)

    6. Secure pipe to water pump with bolts removed earlier.

    Job Done!

    Note: A long Flexible Socket 1/4" Extension will make the job a whole lot easier in my opinion

  4. #4
    Join Date
    Sep 2013
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    I have also just replaced my intercooler hoses on my 2.2 with allisport silicone items, the allisport kit comes with all 3 hoses. Never had to remove the water pump or any other hoses. It is a pain but easily doable, took around 40 minutes

  5. #5
    Join Date
    Feb 2008
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    I have the silicone hoses sitting in a box somewhere in the shed. Havent put them on yet as I dont have the clamps. Rumour has it that they are best fitted with t-clamps.

    What do you lot recommend?
    What sort, brand, size etc....?

    Cheers
    2015 Defender 110

  6. #6
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    I re-used the original ones which are fine. That said T-clamps would be nice I if you can readily find them.

  7. #7
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    Quote Originally Posted by dazzler View Post
    I re-used the original ones which are fine. That said T-clamps would be nice I if you can readily find them.
    Same here, reused the old clamps, i think making sure the spigots are clean and free from oil is important

  8. #8
    Join Date
    Jun 2014
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    Quote Originally Posted by dazzler View Post
    I re-used the original ones which are fine. That said T-clamps would be nice I if you can readily find them.
    Blackwoods have those clamps on the shelf in some stores. All different sizes too.

  9. #9
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    Note: BAS PUMA 2.2L HOSE KIT are "5 PLY" so expect a degree of resistance during installation. I am very happy with mine, would highly recommend it

    pd

  10. #10
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    What a mongrel of a job!

    I'm not the most challenged out there with a spanner but replacing these hoses is a bastard of a job. Just getting the new hose onto the upper intercooler outlet is taking forever, other end to the throttle is ok. I end up giving up as humidity here is around 90% right now.
    3 attempts to fit this, maybe tomorrow will sort it. Time for a cold beer.
    On a positive, my new Bundutop - Bundutec roof top tent is being sent tomorrow.
    That'll be easier to fit than the hoses!
    Ken
    2012 Defender 110 (A silver one!)
    Defender:LS3 6.2 V8 and 6 Speed Auto, ARB BP51 shocks, springs, Damper, Gwyn Lewis running gear, Superior Engineering Radius arms, Long Ranger tank, Recaros', Dual battery, LED lighting, ARB Lockers etc etc.

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