Defender Puma 2.2 intercooler hose to throttle body should be replaced

[ozrob]

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 (http://www.siliconedirect.com.au/90-Degree-Silicone-Reducing-Elbows.html)
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.

[Tombie]

Kits do come with it..
https://www.aulro.com/afvb/images/imported/2016/10/521.jpg

https://www.aulro.com/afvb/images/imported/2016/10/522.jpg

[dazzler]

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

[komaterpillar]

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

[karlz]

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

[dazzler]

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

[komaterpillar]

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

[Beery]

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.

[dazzler]

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

[Baytown]

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

[dazzler]

Ken,

Hand access to the intercooler Inlet is lot easier if you partly unscrew and move the lower half of the fan shroud out of the way. Similarly remove the bent metal pipe for hand access at the throttle body end.

Now some mod ... Since the new hose is a bit thicker it sits very snug to the lower fan shroud in my case and "May rub" so to get around this i have used some of this with the flat side glued to the shroud and the corrugated side cradles the hose:
https://www.aulro.com/afvb/attachment.php?attachmentid=119133&stc=1&d=1485685980

Good luck tomorrow

Cheers,
pd

[Baytown]

Thanks for the info PD.
Yep, it's tight in there and I've got the skun hand to show for it. I'll take your tips on gourd and remove the shroud, I'm just wasting time and energy other wise.
Good on you.
Ken

[dazzler]

No worries Ken!

By the way consider using new clamps as I ended up replacing the original hose clamps

[ninetubes]

is it legitimate to lubricate the ends of the hoses/fittings to help get them on? like a squirt of silicon spray? or it that increasing blow-off likelyhood?

[Tombie]

is it legitimate to lubricate the ends of the hoses/fittings to help get them on? like a squirt of silicon spray? or it that increasing blow-off likelyhood?



Being very serious - Use Personal Water based Lube.
Dries off and doesn't lead to the hoses sliding off under pressure.

[Baytown]

What flavour works best Tombie?😉

[Tombie]

What flavour works best Tombie?[emoji6]



UltraGlide, allows you to take a Cadillac and park it in a Dog house!

[ninetubes]

so i ventured into the garage last night armed with my lube and a can-do-attitude, to undertake this the final of the 3 IC hoses I've replaced. I used the BAS ones with the up-rated IC.

I opted for the "remove the steel pipe and pre-fit the elbow" method which took me about an hour.

for any one interested, here is what i found was req'd:

1/4" flexible drive & 7mm socket - for hose clamps
OEM style self retaining hose clamps - hard to get the loose ones into position.
10mm spanner - for the steel pipework
personal lube (and suitable excuse as to why you're disappearing into the garage with it!)
long screwdriver - used from underneath, handle end against the hose to help push it on
Gloves - to help reduce blood loss
Arms the size of twigs
A mild self-harm disorder
A burning desire to finish what you started

this is best summarised a job for someone else...


interestingly, i'm glad i did it, as the hose clamps were pretty loose and i wouldn't like to be trying to push it back on by the side of the road/scrub. The bolts for the steel pipe by contrast were tight enough to hold the whole car together.

[Tombie]

Works well doesn't it.... [emoji48][emoji56]

[El Rey]

so i ventured into the garage last night armed with my lube and a can-do-attitude...

I bet that's not the first time hey

[Grappler]

Just did a running repair on split intercooler output hose. Used silicone rescue tape covered with duct tape then secured with metal cable ties.
Would be an ideal time to upgrade the whole air system with silicone hoses.

Is Terra Firma TF 742 the correct kit for Defender 2012 2.2 with turbo hose recall modified alternator bracket to prevent turbo hose catching on steering? Any help apreciated as I want to order the correct kit

[Baytown]

I'm not sure about Terrafirma, but the BAS kit is 5 ply and you'll get it in a week.
Theres lots of 4 ply out there.
Expensive shipping but recommended.

Ken

[Tombie]

Wouldn't consider anything other than BAS

[komaterpillar]

I got the terrafirma hoses, they were so **** i didn't waste my time fitting them. A little while later i got Allisport hoses and they seem pretty decent.
Postage at the UK end was really good - they left the UK the same day i paid for them. however they sat in Aussie customs at Underwood for 9 days!

[Grappler]

I got the terrafirma hoses, they were so **** i didn't waste my time fitting them. A little while later i got Allisport hoses and they seem pretty decent.
Postage at the UK end was really good - they left the UK the same day i paid for them. however they sat in Aussie customs at Underwood for 9 days!

Without fitting how did you assess the Terrafirma hoses as ****
Did they have visual quality defects?

[dazzler]

Without fitting how did you assess the Terrafirma hoses as ****
Did they have visual quality defects?


I have experience with both, I have BAS now which is a far superior product compared to Terrafirma. That said Terrafirma kit would be an improvement on Stock/OE.

[Tombie]

That said Terrafirma kit would be an improvement on Stock/OE.

In much the same way a 100km drive in a clapped out Hillman Hunter is better than walking the same in thongs [emoji48]

[djam1]

In much the same way a 100km drive in a clapped out Hillman Hunter is better than walking the same in thongs [emoji48]

Would be OK if you had decent foot wear though.

[komaterpillar]

Without fitting how did you assess the Terrafirma hoses as ****
Did they have visual quality defects?

The TF742 "kit" didn't come with the hot side hose - the one that most commonly fails. Not sure if this was a mistake or not but whatevs. They were bloody thin, I can't remember how many ply they were but wow they were thin. So just straight up ordered a different set.

[Grappler]

The TF742 "kit" didn't come with the hot side hose - the one that most commonly fails. Not sure if this was a mistake or not but whatevs. They were bloody thin, I can't remember how many ply they were but wow they were thin. So just straight up ordered a different set.

You are correct. The TF742 does not have the turbo to cooler hose. Just ordered BAS kit as suggested
In the meantime, Im hoping my repair with rescue tape and stainless cable ties will hold. Its lasted 800km so far

[Grappler]

Finally found time to change out the turbo hoses.

I unbolted the water pump and swung it out of the way. One extra bolt after metal tube is unbolted Plenty of space as you can see in the pic. Even my old thin skin didnt let blood out!
The BAS hose kit mentions trimming the turbo end of the hose on RHD. I needed to trim about 12mm off both ends of the elbow under the thottle box to get it to fit without fouling engine mount bracket.



124789

[landoman]

Thinking of changing my 8 year old Intercooler hoses before they let me down

reading this looks like the BAS kit of 3 hoses is the way to go

also thinking might be a good time to also upgrade the Intercooler ( BAS or Allisport ??……any comments which might be better ?

So as this is quite an expensive item my question is would it make a noticeable difference to the pick up of my 2.2 defender ? I find the pulling out into fast moving traffic and my lack of pick up in speed a tad disconcerting at times . That would be my only reason for making this expenditure.

[DazzaTD5]

Thinking of changing my 8 year old Intercooler hoses before they let me down

reading this looks like the BAS kit of 3 hoses is the way to go

also thinking might be a good time to also upgrade the Intercooler ( BAS or Allisport ??……any comments which might be better ?

So as this is quite an expensive item my question is would it make a noticeable difference to the pick up of my 2.2 defender ? I find the pulling out into fast moving traffic and my lack of pick up in speed a tad disconcerting at times . That would be my only reason for making this expenditure.

Then don't bother as it wont make squat difference in (noticeable) performance.
Even running them on a Dyno, I cant see a difference, considering dyno readings will vary between EVERY engine and other variables such as temp, mileage, snorkel, tyre size etc.

The big improvement is:
*Tuning (pref on a dyno).
*doing a de-cat (for offroad use only)
[bighmmm]

*Eventually the 3 turbo hoses will fail, might as well fit silicone ones when they do.
*Eventually the intercooler will split, so a all alloy one will last.
*I've fitted dozens and dozens of the terrafirma hose kits and i've not had one fail.
*but I have had some of the brands listed here fail, so work that one out?

*TF742LATE is the (terrafirma) hose kit for a 2.2 Defender.
*The elbow on the plastic intake I still use a genuine one and typically replace them at 100K.

[landoman]

Then don't bother as it wont make squat difference in (noticeable) performance.
Even running them on a Dyno, I cant see a difference, considering dyno readings will vary between EVERY engine and other variables such as temp, mileage, snorkel, tyre size etc.

The big improvement is:
*Tuning (pref on a dyno).
*doing a de-cat (for offroad use only)
[bighmmm]

*Eventually the 3 turbo hoses will fail, might as well fit silicone ones when they do.
*Eventually the intercooler will split, so a all alloy one will last.
*I've fitted dozens and dozens of the terrafirma hose kits and i've not had one fail.
*but I have had some of the brands listed here fail, so work that one out?

*TF742LATE is the (terrafirma) hose kit for a 2.2 Defender.
*The elbow on the plastic intake I still use a genuine one and typically replace them at 100K.

thanks for that ….some good food for thought

so why do people fit the larger Intercoolers if they make no difference to engine performance
……keep it cooler for towing ??

[DazzaTD5]

thanks for that ….some good food for thought

so why do people fit the larger Intercoolers if they make no difference to engine performance
……keep it cooler for towing ??

a all alloy one is a reliable replacement for a standard 2.2 that will fail eventually.

DieselArmy quote:
"It’s a common belief that installing a larger intercooler will inevitably lead to improved performance. However, like many automotive myths, this assumption is not always accurate"
Bigger Intercooler: Adding A Larger Intercooler Isn't Always Better (https://www.dieselarmy.com/tech/intercooler-conundrum-is-bigger-always-better/)

[landoman]

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



“”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)””

trying to work up the knowledge ( and courage) to do this hose change over

had a good look at the metal pipe that needs to be removed to get access to the elbow ….but I can only seem to be able to see one bolt holding it to the water pump …..where is the second 10 mm bolt hiding ?

[Lagerfan]

had a good look at the metal pipe that needs to be removed to get access to the elbow ….but I can only seem to be able to see one bolt holding it to the water pump …..where is the second 10 mm bolt hiding ?

It's there hiding under the water pump. I had the same question at first but it is there. If I recall correctly two of the three water pump securing bolts also hold the metal pipe in place.

This pic might help:
https://a.allegroimg.com/s1080/118203/d3feffe14733bb3305de695cc6da/RURA-PRZEWOD-POWIETRZA-LAND-ROVER-DEFENDER-2-2-Typ-samochodu-4x4-SUV-Samochody-osobowe-Samochody-dostawcze

[landoman]

It's there hiding under the water pump. I had the same question at first but it is there. If I recall correctly two of the three water pump securing bolts also hold the metal pipe in place.

This pic might help:
https://a.allegroimg.com/s1080/118203/d3feffe14733bb3305de695cc6da/RURA-PRZEWOD-POWIETRZA-LAND-ROVER-DEFENDER-2-2-Typ-samochodu-4x4-SUV-Samochody-osobowe-Samochody-dostawcze
This is a great photo Thanks

Now if I wanted to loosen up and pull back the water pump would I only have to undo 3 bolts …..or do I need to mess with the belt too

[Lagerfan]

Now if I wanted to loosen up and pull back the water pump would I only have to undo 3 bolts …..or do I need to mess with the belt too

You need to slacken the belt tensioner and slip the belt off the pump, no need to remove it completely. Then same when you’re done to put it back on again.

You should be able to find some YouTube clips that demo it, pretty easy once you know how.

[DazzaTD5]

I did a quick video just for you lot [tonguewink]

Defender TDCi 2.2 intake elbow hose change - YouTube (https://youtu.be/ZtAQl9D3FPk?feature=shared)

[Lagerfan]

I did a quick video just for you lot [tonguewink]


Bloody brilliant! Wish I’d had it a month ago but nice work doing this.

[landoman]

I did a quick video just for you lot [tonguewink]

Defender TDCi 2.2 intake elbow hose change - YouTube (https://youtu.be/ZtAQl9D3FPk?feature=shared)
Thanks that really helpful

question ….did you tighten up the clamp that holds the U bend to the metal pipe before
re installing and if so how hard is it to get to the other clamp that holds the U bend to the throttle body once the pipe is back in place .

once the pipe is back in place I just can’t see how you get in tighten up that clamp I have big long hands which doesn’t help

[DazzaTD5]

Thanks that really helpful

question ….did you tighten up the clamp that holds the U bend to the metal pipe before
re installing and if so how hard is it to get to the other clamp that holds the U bend to the throttle body once the pipe is back in place .

once the pipe is back in place I just can’t see how you get in tighten up that clamp I have big long hands which doesn’t help

in the video I install and tighten the elbow to the metal pipe.
Once in place the other clamp on the intake is relatively easy to get

[landoman]

[QUOTE=Grappler;2685734]Finally found time to change out the turbo hoses.

I unbolted the water pump and swung it out of the way. One extra bolt after metal tube is unbolted Plenty of space as you can see in the pic. Even my old thin skin didnt let blood out!
The BAS hose kit mentions trimming the turbo end of the hose on RHD. I needed to trim about 12mm off both ends of the elbow under the thottle box to get it to fit without fouling engine mount bracket.



124789[/QUOTE



i think as it only one more bolt to remove I’ll go this option as it will give a bit more room for my ham hands

question ………if I unbolt the coolant pump as above is there any gasket that I would need to replace and am I likely to get coolant spilling out all over the place

forewarned is forearmed

appreciate all the excellent info …….I’m a bit of a novice mechanic and appreciate all the great help