Replacing the ends of the intercooler hoses with Riordanco parts

[michaelrking]

I have seen a couple of threads with some pics, but not a complete writeup, so here it goes. After reading the horror stories about blowing out the hoses to or from the intercooler, and planning a 2 month road trip this summer, I decided that 2 bills was a reasonable insurance policy against going into limp home mode in rural Mississippi or some other highly developed area. Here is the link for the parts
http://www.riordanco.com/our_products_catalog.htm#sprinterCrackedHoseFix

First, let me say that the entire evolution was shockingly easy. Anyone with enough sense to use a rachet and screwdriver can do this, in the street. The parts are easy to get to, and there is enough clearance that you don't need to jack the van up. There are a few minor points that a picture or two would make much easier, so I tried to get the relevant bits.

The drivers side is easy to reach, and I understand this is the likely failure, so do it first, it will get you ready to do the passenger side. You can push the ends of the clip forward with your fingers, you only have to go a little ways to clear the ears. The hose should slide right out. Remove the O-ring, clean it, then lube with a drop of oil.

[michaelrking]

Here is the receptacle, with the clip both engaged and disengaged, so you can see how far you have to push it.

[michaelrking]

With Pics

[michaelrking]

Take a picture, or mark the hose to remember the orientation of the ears. Now we cut off the metal end, and replace with the beautiful billet aluminum end. Install and tighten the clamp, make sure the orientation is the same.

[michaelrking]

Check the clip, make sure it's in place correctly. Now reseat the other end and tighten with an 8mm socket. Don't mess with a screwdriver.

[michaelrking]

Now for the passenger side. It's much the same as the right, but harder to get to. Here is the secret. The clip, while performing the same function, is different. There is a 90 degree bend in the end of the clip, and a matching groove in the intercooler end. You can't slide it forward like you can the drivers side. A big screwdirver will pop it loose, you have to get both ends out of their grooves and forward a little, like a half inch. Second pic shows it more clearly once the hose end is out.

[michaelrking]

Install the second hose end like the first. Lube the o-ring with a drop of oil. This one required some finessing to get back in. First pic shows how it goes in, second shows it seated. Third shows what looks like the clip seated, but a mirror reveals the clip is not in the channel on the far side. Fourth shot shows clip seated correctly. Replace the other end and tighten clamp. Go have a cold beer, and congradulate yourself on a critical improvement to your Sprinter!

[BBlessing]

nice write up.

bb

[michaelrking]

Was tooling down the interstate in north Florida when I felt and heard a huge thump, like I had hit a dog or one of the big "pavement pelts" shed from a semi. I was watching the road and had not seen anything, so I wondered if I had hit a buzzard or something with the "forehead" above the windshield. The engine started running rough, with little power. I pulled off at the next exit and looked the truck over and under, but didn't see anything. Limped into the next town and had an AutoZone read the codes, the CEL had come on at that point. Once the guy mentioned one of the codes being turbo pressure, I guessed what it was. I went out and looked, sure enough the driver side hose was completely off of the adaptor I had so proudly installed above. Since I was at the auto parts store, I purchased another clamp with the big plastic ears on the screw head, reconnected everything and drove away fine. The above clamp was completely gone, so I don't know if it loosened up and just slipped off, or if it stripped or broke. I will carry an additional clamp in my emergency supplies from now on, it could have been more painful in different circumstances.

[Aqua Puttana]

Around boats it is SOP to use double hose clamps, especially on thru-hull fittings below the water line. If you consider this, check that the hose barb is long enough to fully seat a second clamp to or it may actually be detrimental. (I couldn't tell the size from the pictures.)

Nice Write-up by the way. Too bad the adapter actually caused the problem it was designed to avoid.:rolleyes: At least the repair solution was easy. vic

[michaelrking]

I now have both adaptors double clamped. I was wondering if since the factory only single clamps the other end, if they consider that sufficient? My guess is that since it clamps to a fixed object, and the other end to a continiously moving object, a single is sufficient. Haven't heard of that end blowing off in any posts I have found.

[Working Retired]

Great write-up and pics. Did you also buy new hoses when doing this job? Any more problems with the clamp coming off after the first time? I've been planning on doing mine, but was intimidated ... until I saw your posting. Thanks!

[sprintguy]

Just a word of caution : Just recently had a camper conversion show up at the dealer with these hose ends installed ( 2 clamps on ), Customers problem was Hose on drivers side keeps blowing off.
I fear this will be a common issue because there is not enough lip on the end of the hose end to keep the hose on while under heavy boost. I Replaced the problem part with the revised drivers side hose supplied by MB , The revised hose has been known to be as good as any rubber hose can be under pressure.
History note: The original hose in question ( drivers side, 07 and early 08 model year) had an issue of tearing at the coupler due to the hose not being long enough ( or at the proper angle) to withstand the pressure and engine movement combined. The redesigned hose is longer and shaped to handle this combination better. Do not destroy a perfectly good hose without thinking long and hard about this point : most charge lines are covered by warranty for quite some time ( if you destroy it ... you own it )
My opinion is that these ends are more of a gimmick than a fix (but that is me)

Carl

[jdcaples]

There are pictures of the two factory hoses that Carl mentioned in the first posting of this thread:

http://sprinter-source.com/forum/showthread.php?t=10345


-Jon

PS: These are the left-side/driver-side hoses, the newer, improved factory part and the older, inferior factory part. I'm really not concerned about the right-side/passenger side hose, myself.

[michaelrking]

Looks like Mercedes has engineered a solution to the original problem of a too short hose that had a built in failure point due to the crimped connector. In that case, I would certainly use the revised factory part. Too bad the organization didn't offer the new part, if not in a recall, in at least in some low cost replacement path. The idea that we will just replace the part under warranty once it fails, (endangering the lives of passengers, days wasted due to a $130 part, tow bills from far away places) is not good for customer good will, to say the least.

[jdcaples]

Looks like Mercedes has engineered a solution to the original problem of a too short hose that had a built in failure point due to the crimped connector. In that case, I would certainly use the revised factory part.

Too bad the organization didn't offer the new part, if not in a recall, in at least in some low cost replacement path. The idea that we will just replace the part under warranty once it fails, (endangering the lives of passengers, days wasted due to a $130 part, tow bills from far away places) is not good for customer good will, to say the least.

You can't order the old part any more.

I'm not sure enough new versions of the parts have been purchased and installed to warrant a recall.

It's common practice for Big Business to look at the number of "new/revised part purchases," estimate the number of non-failures and make a business decision to not inititate a recall. I don't know what the secret formula is... it could be something like this:


"We (daimler) have this new intercooler hose available. We estimate there are 100,000 Sprinters that might use it are still on the road.

We have sold 80 of these revised parts of these to dealerships. Of those 80, only 40 were installed at the dealership. We sold, 50% or 40 hoses to some really hyper-vigilant Sprinter-Source members who replaced their hoses on principle, not because the original part failed.

In conclusion, we estimate a failure rate of 40 out of 100,000.

All those in favor of a recall raise your hand. Hmm... ok. You're all fired. Next order of business.... who hasn't paid us to be on the MB229.51 spec sheet this month?




Ok, seriously: I really don't think mine was on the brink of failure.

I just did it because I had the part, the weather was nice and I didn't have anything more compelling to do.

I probably replaced my hose just to get out of doing some chore like cleaning the gutters or something equally unappealing.

-Jon

[Chandlerazman]

I just did it because I had the part, the weather was nice and I didn't have anything more compelling to do.

I probably replaced my hose just to get out of doing some chore like cleaning the gutters or something equally unappealing.

-Jon



Jon, I am in the same boat now as my business has slowed. With that said, I am trying to do something more compelling, or so I thought as installing an aftermarket cruise control with a wiring quantity that belongs on the space shuttle in a 40 year old British car...
I might as well go back in and vacuum the house :idunno:

[k-man]

I too replaced both hoses with the upgraded factory hoses (08 NCV with 50K miles). I promptly cut the connectors off the new hoses, and replaced the couplers with the riordan billet fittings. I had my first blow out after about 200 miles on the freeway after torquing the supplied hose clamps to the recommended setting. One trip to fastenal for a pair of stainless steel "T-bolt" hose clamps like on all the other diesel turbos and my hoses no longer pop off the riordan fittings.

[jriordan]

I too replaced both hoses with the upgraded factory hoses (08 NCV with 50K miles). I promptly cut the connectors off the new hoses, and replaced the couplers with the riordan billet fittings. I had my first blow out after about 200 miles on the freeway after torquing the supplied hose clamps to the recommended setting. One trip to fastenal for a pair of stainless steel "T-bolt" hose clamps like on all the other diesel turbos and my hoses no longer pop off the riordan fittings.

Hi Guys, Jim Riordan here. I have read with interest your posts on the Hose adaptors and would like to provide some input. First, even the "new" slightly longer hoses still crack at the metal fitting. In our opinion, this is due to the design of the way the hose is crimped in place and the sharp ends of the stock metal fitting. The additional length of the new hose also increases the inherent back and forth "flex" or "wobbling", during engine operation, which increases the wear point so we are not seeing much if any difference in hose life with the new design. Addressing the size of the "flare" machined on the end of our adapters, we wanted to be sure that the flare was large enough to prevent blow off but not large enough to cause a new potential flex crack point. We did experience some blow off with our original clamps and the very first adaptors which had a very small flare. Judging from the excellent photos sent in by Michael King, I can see he has the new parts with the larger flare on the end and the new Norton shielded clamps. Those clamps should not need to be doubled up, but can be. (We are finding that the heaviest vehicles are the most susceptible to any "pop-off") They can be torqued to 100 inch lbs. (we are updating the instructions to call for a change from 60 In. lbs to 100 in. lbs.) Also, before slipping the hose on, even if new, over the adaptor, wipe down the inside of the first couple of inches of the hose with a little windex and a clean rag. Sprinter wizard and friend John Bendit of upscale automotive, has suggested to us a new "T" type bolt clamp (a Clampco 94100-0262 K10) which we will be offering on our website shortly or you can order them from John now. He mentioned it is a little tighter to get on but never pops off. John is opting to use the t type turbo hose clamps on all of his V6hose adaptor installations. (Our turbo resonator eliminators are perfect with the supplied clamps). We deeply apologize to anyone who has experienced a hose pop-off with the hose adaptors and while the majority of our customers who torque the clamps to 100in. lbs are not reporting trouble, we are going to be offering the T type clamp very soon on our site. We strive for 100% customer satisfaction so please do not hesitate to email me anytime regarding any of our products and I will respond. jriordan@riordanco.com. In addition, we have been in the product development business for over thirty years and we will be happy to look at any other problems being experienced by Sprinter users. The Sprinter on our website is ours and we love it. It is a 2006 MB cruiser by Forest River, model 222 and we have had many happy hours in it . . . I have set it up with an inverter and also use it as a mobile office and could not be happier with it. We have never experienced a hose pop off and we are using the Norton shielded clamps @100in lbs on our Hose Adaptor . . Perhaps my favorite addition was the Scan Gauge II which John Bendit told us about. I have fabricated an aluminum rear box mount and motorcycle carriers for the back trailer hitch.

[michaelrking]

The double clamp solution has now held for 8 months. I have towed my #4000 pound camper up through the mountains several times, so the engine has seen some boost. I think I will pick up a torque wrench of the appropraite range and check them anyway. So good, so far.

From a mechanical perspective, it seems like a single clamp of the appropriate size, torqued to the above specs, and located just above the flare should work, assuming the hose itself doesn't fail.

[Chandlerazman]

Hi Michael, I'm glad it's working out for you. By the way, I did get your business card you left on my van a while back! I did want to acknowledge it. Perhaps when I get less busy we could meet up. After all, you are practically my neighbor!

[Bella View]

Just wanted to add something to this post!
I replaced the intercooler fitting before leaving Ca on our way to Alaska with the standard hose clamp provided. Roughly 5000 miles into our trip we were climbing a hill under full boost when I heard the loud pop. First thinking it was a blow out, but then no indication in the steering, I pulled over to find the hose blown off and no hose clamp in the vicinity! When I installed the clamp I made sure it was tight and even checked it again around the 2000 mile mark. I replaced the clamp with a spring loaded clamp I bought from a Bus facility. Since then no problems in over another 15,000 miles. One note; this was on a View MH, when I was scrounging around on a Sunday trying to find a clamp to get me going, I discovered that the clamp on my sewer hose would have worked! I now carry multiple clamps as part of my road kit.

[Aqua Puttana]

Not that you asked...

Wouldn't it make more sense to change the part back to OEM and not need those clamps at all? From many of the comments in this thread it seems the replacement part has caused as many problems as it resolves. The professional Sprinter techs are saying that the OEM replacement parts are fine. One even basically commented that the billet aluminum hose adapter end is a fix looking for a problem. FWIW. vic

Just wanted to add something to this post!
I replaced the intercooler fitting before leaving Ca on our way to Alaska with the standard hose clamp provided. Roughly 5000 miles into our trip we were climbing a hill under full boost when I heard the loud pop. First thinking it was a blow out, but then no indication in the steering, I pulled over to find the hose blown off and no hose clamp in the vicinity! When I installed the clamp I made sure it was tight and even checked it again around the 2000 mile mark. I replaced the clamp with a spring loaded clamp I bought from a Bus facility. Since then no problems in over another 15,000 miles. One note; this was on a View MH, when I was scrounging around on a Sunday trying to find a clamp to get me going, I discovered that the clamp on my sewer hose would have worked! I now carry multiple clamps as part of my road kit.

[JY Appliance]

I also bought that kit to replace the hose end that I at the time had no problem with. After the up grade i also had the hose pop off 3 times. Thank god the clamp was still there.. Crawl under and put it back on wile on the side of a highway. Last time when home i cleaned it good and put 2 clamps on it. I would like to replac it with a stainless wrapped hose. No expansion. Clean it good and alittle glue and 2 clamps.

[dvoyer]

JY Appliance, do you have worm type clamps or T-clamps ? I ordered two hose adapters last December from europarts and I received T-clamps with each kit. I did not installed those adapters yet, but I'm glad to have read this post, I will probably install it anyway on my 2007, but I will torque clamps to 100 in. lbs.
Dominic

[michaelrking]

Michael here again. Last weekend, towing my #3500 pound camper for a birthday weekend up in the yellow aspens, I blew a turbo hose. Not at the Riordanco fitting this time, but a split about 3" back from the intercooler end. Towing a camper up 4000 vertical feet over 50 miles in limp home mode is great fun, you should try it sometime! People love it when you are doing 25 mph up a pass. :-(

We had called the next Dodge dealer (fortunately it was a Friday) and they said to bring it in and they would look at it. I finally crawled into Chapman Dodge into Payson, AZ. Went to talk to the service advisor, he flatly told me they don't have any Sprinter equipment, they couldn't touch it, you need to take it back down to Phoenix. Grrrrr....

I went across the highway to AutoZone, they came out and read the codes, came up supercharger something, but pointed to the turbo hoses. After a more detailed inspection, I found a split in the passenger side hose. I went back into AutoZone and bought a tire patch kit, and 4 hose clamps. I cleaned the dirt and oil from the hose with a wet wipe, and glued 2 layers of patch on with the rubber cement, then swaddled it with hose clamps. Truck ran like a Sprinter for the rest of the trip!

Once I got back to Phoenix, I bought 2 new factory hoses and installed them. I guess this reinforces the lesson that every NCV2 owner should carry a spare pair of hoses, and the tools to change them on the side of the road.

First picture is patch in place. Second is showing the tire patches without the clamps, third is showing the split, and the patch that wasn't adhereing very well, but with the clamps it held enough pressure that I got back down off the mountain.

Maybe reading this will help save somebody else stranded in the mountains with a blown hose. Cheers!