MK5 GTI - Intercooler Hoses leaking again. Replacement suggestions please.

[ZoliWorks]

You dont need to worry about the turbo side as that doesnt leak 99% of the time, but if you want to get rid of that, you should get a k03 silencer removal kit from ebay/aliexpress. I got mine from ali from a firm called Volm. Fitting was perfect, seal was perfect. worked with the oem discharge pipe. I got a k04 version but there's a ko3 version too.



As for the intercooler side, yes that's an option. Cut down the quick connect housing, measure your discharge pipe to intercooler rubber hose diameter and get someone to weld you an aluminium extension of the same or slightly smaller diameter. If possible, get them to do a dent in it, so the collar has something to grip so it doesnt just slide off.



Note: Tried adding images to post but they dont seem to be uploading. I've included imgur links instead.

[pudding]

The problem is the internal bore of the metal discharge pipe wears away from engine rocking, which no amount of new seals will fix.

In the end I got a very low mileage S3/6R discharge pipe with a mint bore and a 6R intercooler and the problem went away.  I also went with the S3/6R boost hoses as cutting the bayonets off the stock hoses isn't quite as good. Reason being the K04 rubber hoses are bigger diameter than the Ed30/GTI ones, so you're leaving some flow on the table using skinnier hoses.