Plastic tube repair question

[scot850]

I am working on the 02 XC70 remedial work. One of the items I found bad (or possibly caused) is the plastic intercooler to throttle body hose.

It is a pig to remove, and with the benefit of hind sight, I should have loosened the pipe clip on the intercooler end so it could move, and the done the same at the other end at the throttle body. By loosening the TB end, and removing the intercooler end there is not a lot of room. The old plastic tube ended up with a hairline crack in the middle 'flex' point where the tube had ben moved rearwards.

Today I was lucky to find a replacement at the junkyard. On getting it home and cleaning it, I can se it has been stretched in the same joint but not split.

So here is the question. Any suggestions what I could use to prevent the joint splitting and also perhaps also fixe the original?

I'm thinking it needs to something flexible. I had originally thought of using my go to, JB Weld plastic glue. My concern in using that is it may make the joint worse and cause it to split as the JB Weld plastic glue is not flexible.

Can anyone suggest anything I could try and use?

Thanks,

Neil.

[jonesg]

i'd try cleaning with brake kleen , rinse with acetone, apply a bead of black rtv sealant and wrap with gorilla tape.

[scot850]

The plan sounds good, but would using some form of flexible heat resistant glue first, then the RTV and gorilla tape be a better solution?

I'm thinking if the plastic is stressed, would RTV sealant and gorilla tape prevent it stretching and cracking. I was also thinking of trying this in the cracked one as well as an alternate until I con find a better used one I can try and remove myself minimizing the stressing on that one joint. I had thought about the plastic glue, but I'm thinking the heat from the engine might be more than the glue can take. I think there is a high temp JB Weld but not sure if it works with plastics. Similarly with Gorilla tape, how temperature resistant is it?

Worth a shot anyway, as I have to get this back together by the end of next week to confirm if the engine is good for the potential new owner to decide if he wants to spend more money on it.

Many thanks for your suggestion!

Neil.

[jonesg]

I used hi temp rtv sealant by permatex on my aft cat flange joint.
it sticks like stink.

https://www.amazon.com/Permatex-81630-U ... rce=1&th=1

[cn90]

Hardware stores (Home Depot) sell some rubber coupling used to join 2 PVC pipes together. Maybe you can modify it to reinforce the Volvo plastic pipe.

Any photos of your current problem?

[scot850]

Yes I do. I'll have to upload later. Thanks for help guys!!

Neil.

[volvolugnut]

Would fusing the crack with heat or plastic welding retain flex?
This is a problem for many vehicles. I have replaced a couple because of leaks.
Actually, I just remembered flex cracking of the points at the front of corn harvesting headers also have this problem. These are made of polypropylene and can be plastic welded for repair.
I will guess that these tubes are also polypropylene.
volvolugnut

[scot850]

I have a mall cheap propane plastic welder (basically a butane powered soldering iron). My worry is that the plastic is so thin than any heat will puncture it completely. The welder comes with some different plastic weld rods. I might try repairing the original first and then look at the options for the un-cracked but stressed joint version.

Thanks for inputs guys Plenty of good suggestions to work with here. I WILL update with pictures this evening!

Neil.

[scot850]

Well, finally got some pictures uploaded:

Original intercooler to TB plastic pipe

At the top of the picture you can see all the oil sprayed from the split turbo to intercooler inlet rubber hose. This is from an 01-02/03/04? turbo engine car. I believe this is only fitted to 01-02 turbo cars, but I found one on an 04 S60 turbo, but an 04 XC70 had the newer version without the MAP sensor and the inlet temp sensor (already removed from pipe)

Oil splash from split rubber intercooler hose

Below the crack in the intercooler to TB pipe at the middle flex joint of the original pipe

Crack in original pipe mid-pipe flex joint

Below is the stress point on the 'new' pipe:

New pipe stress point in mid-pipe flex

Sorry for the delay!

Neil.

[cn90]

Do Volvo dealer still sell these pipes for P2 cars?