I wonder if the wear is cause by vibration (the parts rubbing together) rather than heat? How tight are the motor mounts?

 

I can assure you that it's melting against the manifold. I went and checked again and it was sitting on it this time.

 

One of the first parts I replaced on my car.

Then proceeded to rub on the cooling fan connector. I moved the connector to another standoff on the shroud.

To be honest, your hose is very swollen on the bottom there. Even looks like it's dry rotting too. Also looks like the clamp might be a little tight, or the hose is just that old.

Replace ASAP.

 

For whatever reason, it won't let me save changes to my post.

Here's a link to the hose/part number: http://www.volvopartswebstore.com/p...cts/Volvo/2004/S8029l-6-cylinder-Turbo-T6/Charge-air-hose/1103262/30637460.html

 

also i noticed that there is a small opening ( ithink) . i have marked it withred.
meaning its not properly flush. maybe you should loosen the clip and push in the pipe properly.

 

Well before the day ended my dad quickly solved it by taking a typical bolt (the ones off of bicycles that secure the tires to the bicycle's frame), and he put it between the lower and upper plastic turbo hoses that are screwed together. He told me to put it between the two plastic turbo hoses, so the screw (we found a compatible longer screw laying around) could go right in the bolt hole and down into the lower turbo hose where it screws into. We also completely took out the turbo hose and re-seated it, so it doesn't bend its way back down towards the intake manifold. Dad and his brains, plus my two hands = job finished! Check it out!

One thing I do question though, is that the hose has been really screwed on tight...

 

This is really annoying how we can't correct, or edit anything. They must be "remodeling" the website, or they're working on it it seems. I didn't want to have for you guys to click on the link, but instead just to see it there... -.-

 

Yeah, here's mine:

http://i1343.photobucket.com/albums/o784/slowcarsguy/2013-10-25001009_zpsceb89f09.jpg
http://i1343.photobucket.com/albums/o784/slowcarsguy/2013-10-25001004_zps5127088c.jpg

You need a new one, then you can go back to the factory setup.

The one you have is swollen. Either it already leaks or soon will.

 

Wow your's is close too! That's scary man. I don't think that I would have considered this to be an issue, but it occured to me. It's so lame how it's designed, all up-close and tight like that. I would try what we did Matt, and it really wasn't hard (I just wasn't creative enough like my dad LOL, he made it seem so simple).

As for my hose, I'll take another look at it tomorrow probably and check the hose itself. Its been melted through the inside. There's ripples and junk like that inside of the hose because it got melted from the outside. I'll shove it in deeper to the plastic tubing and I'll preventbably just call it a day.

 

... probably*. Not preventbably LOL.

 

Matt's hose isn't as close as you probably think it is. It's just the angle of the pic. This hose issue is a common probably when these T6s get up in mileage. I think the initial probblem is oil getting blown through the hose by the turbo which is pretty much unavoidable. Then the oil slowly eats away at the rubber causing it to swell, expand, and lose it's shape. Then it sags down on top of the hot intake manifold and already weakened, it melts away.

As Matt said, you need to replace that hose. If it comes apart on you, the car will shutdown immediately and you will be stuck on the side of the road.

 

This is exactly what I was getting at.

I'm sure if you take the hose off, there will be signs of oil on the inside of the hose right where it failed. I know my original hose had buildup there, and my new hose continues to show a little buildup there as well.

Turbo seals might be failing, or perhaps the PTV heater is dead. Flame trap is clean.

 

Matt, I was browsing through your photobucket account and I saw that you have a forge recirc valve installed. I have one that I am planning to install tomorrow. What difference, if any, did you notice with it?

 

I can hear the valve venting only when the window(s) are down. There is also a little bit of a chirp which is apparently common with the design.

I had leaks at the hoses, figured I'd replace the valve with something nice as well as new hoses. The lower hose is discontinued by Volvo.

 

I wasnt too concerned with hearing anything... I was interested in seeing if it performed its job any better than the stock cbv. (Holding/releasing boost... that kind of thing.) Mostly, I asked because I've always considered that an unnecessary upgrade if the stock cbv delivers the same results, and you are in a position to agree/disagree with my assumption.

I've got the forge recirc valve with the ext. Discharge horn to use with my conversion project, so I'm confident that it'll make some sort of noise(s).

 

The stock CBV isn't that bad of a design, but it can fail with higher boost etc. There's the VW 710N bosch valve which is supposed to be good for 20 PSI or so. So Bosch did fix the design and make it more reliable.

The CBV doesn't really seem to do much in terms of boost namely because my car has amazing boost surge issues which apparently aren't affected by the CBV, TCV it seems. New Bosch MAP/BPS, MAF, reset the ECM etc.

For now, I think I'll try a new factory TCV and some new O2 sensors to try and pickup some fuel economy and extend the life of the cat.

 

Supposedly the VW guys notice boost tapering off more than usual and boost not returning as quickly as normal on shifts.

So unless those are the issues you're having, won't be much of a difference.

I honestly didn't notice much of a difference with that.

Likely because of the other issues.