Recently I posted regarding a strange hiss that seemed to be emanating from behind the head. I had searched everywhere and couldn't find the source. I had also recently replaced almost all my cooling components (valve, caps, rad, etc.) and figured it couldn't be failing already.

Well it turns out it WAS related to teh valve, but it was the air hose and not the valve itself. It seems that somehow the valve melted a tiny bit or was damaged previously, and whatever did it left a tiny little hole about 6" from the valve connection. Since the hose kind of wraps around and away from the driver's side as it circles to the firewall entry below the sound was always away from me (hence it sounded like it was coming from behind the head) and I couldn't ever see the hole. I did inspect the hose previously, but I guess I just missed that tiny little hole.

So, does anyone know a good way to repair this little plastic hose? Will a good wrapping of electrical tape for about 3" around that spot seal the leak? Its not very big and the pressures here are less than 14psi or so I believe, so I figure it should. If not, is the hose easily traceable? It leads to the climate control vacuum thing atop the radio, right? I could just tape a new one to it and pull them through? Sounds like a PITA...

Thanks in advance and for all the help from people who replied earlier.

-rt

There's an excellent product called Extreme Tape. I got it a Part Source here in Ontario. It is a silicon self-adhering tape that bonds to itself. It is electrically insulative, air tight, watertight, withstands extreme temperatures and high pressure. I used it on a big crack at the underside of my turbo intake air hose while I waited for the replacement hose to arrive. That was 6 months ago. I have the new hose but figure I'll save it until the repair job leaks. I bought a 2nd roll of the extreme tape for road side repairs, as it could be a real life saver for any hose that blows a leak.

Al

you could always just go get some epoxy and epoxy the hole, that stuff set's like concrete once setteled it will seal the hole, the only down side is you loose alittle bit of flexability in that section where you put it. it would be a perm fix if you dont want to cut the hose or what not, i would only use this option if you cannot cut the hose, cutting the hose and putting a straight hose coupler in is much better and would probly last the entire length of the hose itself.

Tape may be temporary because of high underhood temperatures. One solution is a combination of "Goop" adhesive and a piece of rubber hose sized so the inner diameter of the hose matches the outer diameter of the plastic tubing. Another is to cut and splice the tubing using a flared fitting at the site of the hole.

Yeah, I hear you on the heat with the tape (that dawned on me as well). Patching with goop is kind of tough though given the hole. It's more of a "dig" out of the hose where it melted back or something or got cut into by something. This means in this one tiny little spot its actually like half a hose, and I'm worried goop anywhere near it would just close up the hose entirely (though I grasp what your talking about whit a hose over a hose kind of thing).

I'm thinking the best route is going to be to either cut out the small section of damaged hose and put in a little pipe around which teh ends of the hose will fit tight. Kind of like the T splitter connection used in the turbo vacuum lines and discussed by aleekat.

The other option would be to get another foam fitting thing like the one on the end of the hose (where it connects to the valve) and use that as a splice. Its the same dimensions and already prevents a leak at teh valve, so I figure it should be good for the middle of the hose as well. I can probably find one on any junker as well, which makes it easy.

Right now I just have it taped up with packing tape, though it is apparently "storage tape" from 3m "specifically engineered for extreme heat and cold" so... :)

Thanks for the post and the ideas.

-rt

Electrical tape will just be a temp fix. You could try some automotive "Goop" sealant. Or just add a nipple(kind of like the t nipple for windshield washer) and cut the bad section out and replace it. Beats pulling through the firewall wall. Seen some guys use a short piece of refrigerator icemaker copper tubing for a nipple.

Yeah, as I said in the post to Ringlee I can see how electrical tape woul dbe a VERY temporary fix (it tends to get loose and melty at heat).

The splice with a mini-pipe idea sounds very good, I'll keep that one specifically in mind this weekend when I try to repair it more permanently.

Thanks,
rt