All BKP engine user should look here, serious potential problem, air intake hose

[han95]

I attached the photos to show the problem. Passat 2007 TDI 2.0 140P
The edge of 140P BKP engine cover contact with hose. As the vibration of engine during running, the edge like a saw to cut the intake hose. The holes on the hose will allow dust or small items to come into the engine without air filter.
Simple replacement the hose may not solve this problem. Does anybody know a solution?
Thanks a lot.

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btw, who know the part number of this intake hose? I find it on the ebay, but it does not look like 100% same as the one on my car.
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[Gazwould]

Vibrating derv engine covers have been chaffing through plastic pipes for years .

I'd be more concerned to re-engineer your oil pump so your engine and turbo doesn't expire .

[han95]

Thank you for reply.
I do not understand what the means 'I'd be more concerned to re-engineer your oil pump so your engine and turbo doesn't expire .'
My oil pump will have problem?

[Rob69]

Ultimate solution is to leave the cover off. Failing that you can check the rubber grommet inserts inside the cover that push onto the ball end bolts for wear, and replace, extend the length of the ball end bolts to raise the cover slightly, fit neoprene strip or cut rubber pads to fit at the likely wear spots.

[han95]

Ultimate solution is to leave the cover off. Failing that you can check the rubber grommet inserts inside the cover that push onto the ball end bolts for wear, and replace, extend the length of the ball end bolts to raise the cover slightly, fit neoprene strip or cut rubber pads to fit at the likely wear spots.

Thanks, entirely remove the engine cover may increase noise from engine. because you can see the sponge under the cover to isolate noise.
I also think to cut a little part of engine cover edge. But the rest thing is how to fill up the hole? using glue?

[Rob69]

Fill up the hole ? you mean in the air intake pipe - no, replace the pipe. Get yourself to a breakers yard this weekend and have a look under the bonnet of golfs, Leon's tourans anything based on that platform with that engine in, pretty sure the pipes will be the same across those models.
I doubt the cover will make much acoustic difference, it's there to make it look pretty and keep fiddlers hands out, if it's giving you these problems a little extra noise will be small price to pay until you come up with a solution ( cutting or otherwise)
Open up the oil pump can of worms at your own risk!!

[Marcuspassat]

Only noticed this same problem on my car the other day, the clip from a hose had just worn a hole trough it.

So I moved the clip upside down so it can't do it it the future and replaced the intake hose. Also attached some hard foam to the area as a fail safe.

Easy fix hope this helps..