
Originally Posted by
RickV
So I can confirm that the review on Amazon is accurate. The housing is manufactured with a flaw that doesn't allow the hose to go in all the way. As you can see in the pics there is a shoulder inside the pipe with a hard edge that shouldn't be there or should have been deeper in. It's very slight, probably chokes down the opening a half mm overall but it's enough. I have some tapered lathes that I am going to put in there and see if they will take that hard edge off without touching anything else. A dremel might work also but I'll try a lathe first.

Originally Posted by
RickV
The dremel worked good. I carefully removed that hard edge by putting a taper on it and the hose slides right in snug.

Originally Posted by
RickV
Thanks guys, these dremel bits worked really well. The fine grinding stone to take the hard edge off and then the abrasive polishing wheel to even it all out. I'm going to try to get it installed on Saturday. I'll post updates as I get them.

Originally Posted by
Rotibajan25
Your write up helped me significantly, so thanks very much.. I just wanted to add this..
I used a 7/16 LENOX saw drill bit first (nothing else fit better, was almost a perfect fit). I blocked the hole with paper toward the back innermost part of the hole so that drilled particles wouldn't fall inside and could fall out once I turned it on the side and I tapped the drilled particles out. I drilled (slowly, holding the drill firm and straight upright not to wobble around) all the way to the inner 2nd lip as you showed in your previous pics.
Then I used the grinding bit for my Dremel to smooth and level inside the hole, checking fitment each step of the way to make sure the hose fit perfectly snug all the way inside, up to the stop after the rubber gasket. Worked like a charm. bolted it all up and it fitted perfectly. I also replaced my oil cooler since it too was original from 2007 and had a small leak. Its a lot of work to redo the process of removal (plus wasted coolant and oil). Everything fitted great and no more leaks!!!
Why?, other than the dealer to make money on repairing these, where these metal housing not used from factory build was straight ridiculous. These were always the way to go.. Follow Rick's steps and these extra things and you won't regret it.. Bless Up!! Good Luck!!
I've recently bought this to replace the housing on my '13 TT-S.
Interestingly it seems the longitudinal engine has a different style of connector for that...connection. You guys don't seem to have the "cloverleaf" type retainer (man I absolutely
hate those things BTW), but I do. I'm not sure how else to describe it other than "cloverleaf" so hopefully you get what I'm talking about. Otherwise I can post a pic.
Anyway, I read on an Amazon review that someone else was able to get his to fit by merely using different o-rings--slightly thinner as in similar ID but smaller OD. I tried this out and it
almost worked... First of all it was indeed the o-rings in my case that were stopping my tube from going in. I removed one of them and then realised there's actually two (the cloverleaf thingy hides the black one--but on yours you can clearly see the two of them). So I removed both the O-rings and found the pipe seemed to just about fit, so I tried using the thinner o-rings and it almost made it but...
The damn cloverleaf collar thing at the end is
ever so slightly larger than the base of the rest of the connector and that seems to hit on that ridge and therefore it prevents the cloverleaf retainer part from locking in around the exterior lip. I tried "just jamming it in" but yeah that doesn't seem like it's gonna work 😄 So I think I'm gonna just see if I can take it back a small bit with the Dremel, as you guys say, and then try with the same new o-rings and hopefully it seals.
In the case of the A4 you may be able to just use the thinner o-rings and not even have to modify it? That's seemingly what the one review on Amazon said, anyway. I'm kind of curious though, how does the pipe on the A4 secure into the port if it don't have the cloverleaf part?
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