Easiest way to put intercooler hose back in place?

Johnny2R · 17th April 2022, 17:31

The intercooler hose has come slightly loose on my 2003 CDT Tourer, and although I actually put the new hose in place myself, with replacement O-rings, it was a fair while ago and I have forgotten what I did. Access is difficult. What is the easiest method, preferably one which doesn't involve removing the front bumper?

75driver · 17th April 2022, 22:11

Quote:

Originally Posted by Johnny2R

The intercooler hose has come slightly loose on my 2003 CDT Tourer, and although I actually put the new hose in place myself, with replacement O-rings, it was a fair while ago and I have forgotten what I did. Access is difficult. What is the easiest method, preferably one which doesn't involve removing the front bumper?

Which end of the IC hose is loose, bottom or top end?
If it’s the bottom end of the hose that connects onto the 90 deg elbow that’s fitted up to the IC, it should be straight forward to fit from above (assuming that jubilee clips have been orientated with hex / screwdriver head pointed upwards for access).
I can’t recall if moving the coolant tank makes access any easier… Im not sure it does.🤔
It’s probably easier to disconnect the top end of the IC hose and fit the bottom end first.

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Johnny2R · 18th April 2022, 08:42

Yes, bottom end. Now I think about it, I'm pretty sure I did move the coolant tank before, which was straightforward enough (single hex bolt to release, I think).

Johnny2R · 18th April 2022, 10:52

Well, what I did, which turned out easy enough, was to move the coolant tank out of the way, detach the intercooler hose from the top of the engine, and disconnect the bend section. I was then able to push the bend section into place and secure it to the radiator (I used a cable tie, although there should be a bolt, don't know what happened to it, but its absence explains why the hose was able to pop off - reckon a cable tie should prove strong enough, though). I then reattached the hose to the bend and then to the top of the engine.

I think where I've had difficulties in the past was in trying to put the hose in place on the intercooler with the bend attached. Attaching just the bend and then attaching the hose to that is much easier.

17th April 2022, 17:31	#1
Johnny2R Gets stuck in Rover 75 CDT Club Tourer Join Date: Apr 2007 Location: Norwich Posts: 712 Thanks: 98 Thanked 47 Times in 24 Posts	Easiest way to put intercooler hose back in place? The intercooler hose has come slightly loose on my 2003 CDT Tourer, and although I actually put the new hose in place myself, with replacement O-rings, it was a fair while ago and I have forgotten what I did. Access is difficult. What is the easiest method, preferably one which doesn't involve removing the front bumper?

18th April 2022, 08:42	#3
Johnny2R Gets stuck in Rover 75 CDT Club Tourer Join Date: Apr 2007 Location: Norwich Posts: 712 Thanks: 98 Thanked 47 Times in 24 Posts	Yes, bottom end. Now I think about it, I'm pretty sure I did move the coolant tank before, which was straightforward enough (single hex bolt to release, I think).

18th April 2022, 10:52	#4
Johnny2R Gets stuck in Rover 75 CDT Club Tourer Join Date: Apr 2007 Location: Norwich Posts: 712 Thanks: 98 Thanked 47 Times in 24 Posts	Well, what I did, which turned out easy enough, was to move the coolant tank out of the way, detach the intercooler hose from the top of the engine, and disconnect the bend section. I was then able to push the bend section into place and secure it to the radiator (I used a cable tie, although there should be a bolt, don't know what happened to it, but its absence explains why the hose was able to pop off - reckon a cable tie should prove strong enough, though). I then reattached the hose to the bend and then to the top of the engine. I think where I've had difficulties in the past was in trying to put the hose in place on the intercooler with the bend attached. Attaching just the bend and then attaching the hose to that is much easier.