how many orings did you use? did you remove the screen gasket and fit it manually or leave that in its normal place

also anyone knows how i can get the TB to shut so I can clean the , its caked.

but i don't really wanna do it by hand and break anything. Its actually a sport

Not anymore, 4.4 TDV8 now

Four o rings and everything else exactly per Furnituremans’ instructions 👍 Jonathan

2007 Defender 90 XS Hardtop

cool will do same when it turns up thanks  Its actually a sport

Not anymore, 4.4 TDV8 now

Evening all. I’ve discovered the source of my air leak and it’s the little hose connected to the throttle body elbow. Can anyone tell me what the dimensions are of this pathetic little piece of wisened old rubber once was on my car? It’s so brittle, when I removed it to check for markings/dimensions, it crumbled in my hand. Still, it gave me the chance to clean the rest of the system and, thanks to FM’s instructions, I’ll be going down the multiple o-ring route to seal it up for the foreseeable.

Thanks folks! -------------------------
2012 4.4 TDV8 Vogue
2001 Audi A2 1.4 16V
2019 Skoda Kodiaq (don't ask...)

Furnitureman wrote:

Like nearly all 4.4 TDV8 owners the rigid plastic connector to the throttle body is leaking, it’s an awful design from the start and most look like this after several thousand miles

Click image to enlarge

The problem is the seal inside really isn’t upto the job and the fit is so loose it’s comical it ever got past the design stage, I’ve been thinking for a while how to solve this issue and I think I’ve done it, this is my connector 2000 miles after the fix

Click image to enlarge

The fix is so simple and costs under £20 and doesn’t involve PTFE tape, to fix this irritating issue you will need the following

Small flat blade screwdriver
7mm socket
3 75mm int diameter 3mm O Rings

To start remove the rubber intercooler pipe using the 7mm socket
Then undo the clamp on the small pipe top right of the connector and remove the pipe
Next in clip the electrical connector bottom left of the pipe
Finally pull out the metal retaining clip and remove the connector
This is what it looks like inside

Click image to enlarge

The seals are usually misshaped and don’t form a great seal, just in front of the seal is a rigid plastic retaining ring to remove this use the small flat bladed screwdriver to pop the retaining lugs inwards like in the picture below

Click image to enlarge

Click image to enlarge

You can put the rigid retaining ring aside, next get the three 75mm O rings and slide them over the metal throttle body then fit the original seal as below

Click image to enlarge

Finally re fit the rigid plastic part, re connect the plug and pipe and re fit the intercooler pipe, after 2000 miles mine is as clean as the day I did the repair

Hope this helps others if you do a search on eBay you will find the o rings

Thank you for the instructions, I bought a pack of 10 from Amazon, next day free delivery using Prime and for under a fiver - happy days to fix this stupid turbo elbow charged air leak

Keywords for searching on Amazon below :

Nitrile Rubber O-Rings 75mm OD 68.8mm ID 3.1mm Width, Metric Sealing Gasket, Pack of 10

Please send a link

sure - but this is the .co.uk site for Amazon

https://www.amazon.co.uk/dp/B07G2VFJKY?psc...ct_details

TomC-RRV8 wrote:

Just for clarification you refitted this without the plastic retaining clip that holds back the original green rubber seal?

I like the idea of this fix, been quoted €280 for new connection and pipe!
Done mine 3 times now with ptfe tape, and it does make a big difference with the DPF readings.
Terrible design I think, anyway, this does seem a solution to the problem, well done for thinking “outside the box” for a cheap way of getting around this problem.
As said before, do you leave the retaining plastic ring out or not, do you smear the new o rings with oil to aid installation?

OP says "Finally re fit the black rigid plastic part, then re-connect the plug and pipe and refit the intercooler pipe, after 2000 miles mine is as clean as the day I did the repair"

Furnitureman wrote:

Finally re fit the rigid plastic part, re connect the plug and pipe and re fit the intercooler pipe, after 2000 miles mine is as clean as the day I did the repair

Hope this helps others if you do a search on eBay you will find the o rings

Sam's Motor and Machines covered this in his latest video.

Around 30min into the video

?si=40Cnra4XK598sH6e 2011 4.4 TDV8 Vogue SE Buckingham Blue with Ivory and clear glass = "Rory"
New Defender D300 90 on order so "Rory" will be going to a new home....!
1974 Series 3 Lightweight = "Millie"
My preferred specialist: www.glenrands.co.uk
--------------------------------------------------

What I would like to add is to make sure all the tabs of the metal retainer ring sit in the groove in the throttle body, all the way around.
My elbow, the black plastic part, had a little soot on the outside, at 5-o'clock, so to say.
The green OEM seal (it looks like an X-ring, imo) was ok, as far as I could judge.
The metal retainer was a little stretched though, so when I fitted it without the elbow I noticed not all the tabs were in the groove.
So I bend the retainer in several spots and made the ends cross, in other words: the retainer diameter is now less than the throttle body groove diameter.
Now I'm sure all tabs are in the groove keeping the elbow in position. 2012 4.4TDV8
2000 Honda S2000