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Your Turbocharger Hose worn out? » Read more about common malfunctions • Repair • Replacement manual
Forward compressed air by means of the charge air hose
The charge air hose is a component that can be found in charged vehicles. It is the connecting element between the charger and the combustion chamber. The air compressed by the turbocharger, supercharger, or G-charger is forwarded through the air hose for combustion inside the cylinders. Although the charge air hose is a simple component from a technical standpoint, it is important for trouble-free operation of the engine.
Path of compressed air
Turbochargers, superchargers, or G-chargers have the task of compressing the intake air. Denser air has a higher percentage of oxygen. The more oxygen is squeezed inside a combustion chamber, the cleaner, more effective and more efficient the combustion. The engine's performance increases significantly and fuel consumption is reduced. The three modules available for compressing intake air are turbochargers, G-chargers or electric supercharger. Turbochargers are powered by the vehicle's exhausts. G-chargers are directly driven by the engine via a shaft, a belt or a gear. Electric superchargers are powered by an electric motor. The turbocharger is most prevalent, because it is technologically simple and thus comparatively inexpensive. The charge air hose is located directly behind the charger.
Construction of the charge hose
The charger's air hose must withstand higher loads than a simple intake duct. The pressure generated by the charger is 1-1.2 bar (relative). As charging inlet air doesn't just increase the air's pressure, but also its temperature, most intercoolers are usually downstream of many chargers. They lower the air temperature from approximately 140 °C to 90 °C. This further increases the charge air by 0.5 bar. For the compressed air line to withstand both, the temperature and the high pressure of up to 2 bar, the hose must accordingly be constructed to be flameproof. It therefore consists of a mixture of heat-resistant rubber and a tear-resistant fabric.
Charge air hose defects
A pressure hose for the charge air can cause minor to serious problems if leaking. Higher fuel consumption and decreasing performance indicate a small crack in this component. If, however, it slips off or a large area breaks, a sudden and significant loss of engine performance occurs.
A charge air hose can become damaged in three ways: Aging, internal disintegration and cracks. As the charge air hose is a thermally and mechanically highly stressed component, its lifetime is limited. Therefore, many manufacturers prescribe its replacement as part of the maintenance plan. The usual interval for a change is between 2-5 years.
Rubber is sensitive to solvents of any kind. Permanent exposure to hot oil is very harmful to a charge air hose. Thus, if an oil leak is detected by the charger, the hose should be replaced after rectifying the cause of this damage as a precautionary measure.
Incorrect installation of the pressure hose may result in it rubbing against a pulley or a belt. In such a case, the soft rubber is quickly worn off, so that the hose can no longer hold the internal pressure. Another way of external damage to the hose can, for example, result from a raccoon bite. Should this be identified, the entire engine compartment must be examined for further damage. Typical other bite-targets include spark plug wires, water pipes, electric cables and even brake lines. An ultrasound machine is the most effective measure against raccoon attacks. Pressure hose repairs Fortunately, repairing the pressure hose is very easy. In most cases, it is only fixed by two clamps that allow for easy removal and installation. Prior to installation, one should check the charger for oil leakage. The cause of undesired oil must absolutely be eliminated, otherwise much more serious engine damage is likely to occur, in addition to damage to the new spare part. Inexpensive despite brand quality The charge air hose is a comparatively inexpensive spare part. The main manufacturers of this component are BUTCHERS and ATEC. Avoid unpleasant surprises by choosing brand quality. A new charge air hose costs about 30 euro. Other manufacturers offer much cheaper spare parts, however experience has shown that they do not provide the required temperature and pressure resistance in the long term. Therefore, well-established brands are the only recommendation when purchasing charge air hoses.