I *think* I just popped an intercooler pipe off.

[IanH755]

Hi all, under WOT in 3rd at 4500rpm the Revs stopped building, there was a whoosing sound and turbo power was lost. There are no dash lights and the engine is fine when off boost.

I had "exactly" the same symptoms in my C5 when the lower pipe slipped off the right I/C so I'm fairly certain it's just that again but I haven't seen this on any C6's yet.

I'm going to pop into kwikfit or similar to see if I can borrow a set of ramps for 10minutes to confirm it, wish me luck!

[IanH755]

Fixed it, it was the nearside intake manifold pipe had popped a jubilee clip - 30 second fix and something to keep an eye on. I may end up upgrading the pipe and clips on both sides anyway, just to be safe, as the other side needed re-tightening too and the pipe was slightly shorter.

I'm also thinking about doing the other two intercooler pipes as the lower ones were both very soft, probably with some black silicone pipes and proper aerospace clamps.

[Nobby]

Surprised there are no brackets holding that pipe in place too - looks like a lot of movement to me.

[IanH755]

There's a single screw connecting it into the airbox and this has acted as a pivot point. It could do with 1 more point of contact just to prevent the movement really.

Anyway, I'm getting some pipes and clamps from ebay later this week which should help.

[SuprSi]

It's a good job that didn't happen during that epic overtake we did on saturday!!

After your C5 IC pipe split last year I upgraded all mine to wagner silicone pipes for peace of mind!

[RossDagley]

I had a boost pipe come off on a trackday in my pegueot 106 - almost got rear-ended. It's like hitting the brakes!

[SuprSi]

I guess you'd suddenly have less than even NA power when it loses boost, it would suddenly go very rich until the lambda sensors sorted it out.

[IanH755]

Son of a ............. It happened again! The day before a trackday too. At least it's a 2 min fix but what a ball-ache. I think it's during the gear change that the silver pipe pulls outward and backward which pulls the jubilee clip so much it slips off the pipe (as in the pic at the top) but I don't know what causes the movement (failed BOV causing back-pressure etc?). I check it now after every trip and you can see it slowly coming off after a dozen or so full throttle changes!

Audi have no spare pipes in the UK so I might just go back to my original plan of replacing all the rubber pipes with silicone from turbo to intake and fit proper clamps.

I take no other Stage 2 car has had any similar issues?

[don0301]

If the clamps are tight, it wouldn't come off....

[RS6chris!]

Could it be excessive movement in engine block/drivetrain under hard acceleration?....movement causing pipe to come off?

Worn engine mounts perhaps?

Just a guess BTW?

Chris

[Hadies]

This happened to me recently. @IANH755, did you go for an aftermarket solution or OEM?

[IanH755]

Initially I bodged it with a very ugly looking Mikalor heavy duty clamp as a temporary measure until Audi got some new rubber pipes in -



However once Audi had some stock I replaced the OEM rubber pipes on both sides with new OEM ones which have been redesigned to have taller "Lips" for the jubilee clamp to butt up against and is made of thicker/stiffer rubber. I also replaced both jubilee clips per pipe (4 total) at the same time and I haven't had the pipes blow off again since, not even after the 900+ conversion.

Rubber Pipe - 07L145746G (the older version I had from build was 07L145746F)

Jubilee Clips - Either N91175901 or N10544401 will fit. I chose N10544401 as it is slightly wider (12mm vs 9mm) but Audi use both parts.

[IanH755]

Found some better pictures of the whole process showing what was happening and the fix -

This was how the lip of the pipe was starting to slip under the clamp after around a dozen full throttle gear changes -



This was how it looked after the temporary clamp was fitted -



and this is how it looks now with the redesigned rubber pipe -

[Hadies]

Cheers man. I heard the issue before the car spat out an error code. It sounded like a dump valve on gear changes. The error read turbocharger underboost and I noticed the intake manifold pipe wasn't seated properly on the nearside.
I'll go with your suggested fix if it pops out again.
That Mikalor clamp is a beast. I'm sure I've seen something like that on scaffolding

[IanH755]

That Mikalor clamp is a beast. I'm sure I've seen something like that on scaffolding

"Borrowed" it from work and it was massive overkill