turbo inlet pipe to ETM keep on popping out

[2002V70XC]

Guys
I'm having a problem with the turbo to ETM pipe kept on popping out after I already tighten the clamp to the max. I already use a tough metal string to wrap around and hold the pipe against the inlet manifold but it still couldn't solve the problem.
This is the new pipe that I bought from IPD (~$120 USD) to replace the old one that had oil leak at the intercooler. The problem was test drove the car really hard after I finished the PCV job + cleaned ETM + changed spark plugs. I was doing a left turn and started to do a hard acceleration, I heard it popped and the car wouldn't move so I got to the side of the road and inspected it. I removed the clamp and popped the pipe back on to the ETM before driving home at 40km/h. when I got home it already popped out of the ETM again.
I put the clamp back on and tighten it using the 1/4" socket (12 point) and extension. I did the best I could to tighten it, it was until the socket got loose. Maybe I need the 6 point socket to do a proper job but I thought it was really tight. Plus I did use a metal string to hold it around inlet manifold so that it wouldn't be able to pop out hard. I test drove it again and I thought I blew the turbo for pushing it too hard instead of thinking that the piped popped out again. I could do 80km/h -100km/h but it felt like the turbo was gone and the car wasn't performing well.
This morning the engine had a shudder on me after I started the car for 30 secs but it managed to get back to normal so I just drove it like normal thinking it was the turbo charger or the coils. At the time when I left work to go home, it started fine and then the shudder came and my engine got stored in less than 1 minute of driving. I shut down the engine and tried to turn it back on but didn't work. it only started when I put the gear back to P and start it again. I totally thought it was one of the coils or the turbo charger that caused the problem.
I got home and inspected the engine bay. I still thought the pipe was in place because the metal string was holding it properly. I didn't find out til I put my hand under the inlet manifold to feel the clamp. It was out again. My old one never got popped out doesn't matter how hard I test/push the car to the limit.
So my question is: does anyone have a solution to this problem?

[vtl]

Is it OE pipe or blue silicon-based one? Does it have a bead on it?

[2002V70XC]

Hi vtl
Thanks for the reply. I bought the OEM one from IPD:
http://www.ipdusa.com/products/8466/...2002-automatic
I think I might have put the vacuum check valve on the wrong way which might cause some vacuum/air flow problem that leads to this but I'm not sure about the flow yet so i can't tell.

[Tahoe_XC]

Which end is popping off?

[Astro14]

OK, so this is on the ETM?

There just isn't that much pressure there - it's only going to pop off if the connection isn't secure: loose, contaminated, mis-aligned. This engine only puts out about 8PSI of boost, so the amount of force developed under full boost isn't enough to push off a secure connection. Further, this connection is hard to get aligned correctly. I recommend that you invest in a small mechanic's mirror.

- Clean the connection area on the ETM to ensure that there's no grease/oil present. Clean the inside of the pipe too. The PCV system is always putting a bit of oil in the intake under boost, so there is always a bit of oily film when you're doing this.
- Loosen the connection with the intercooler so that there's no pre-loaded tension on the pipe itself, just loosen the clamp so the pipe can rotate.
- Then re-connect this and make absolutely certain that the connection is complete, the pipe is on squarely, and that there is no gap on the ETM surface...i.e. the pipe is seated completely on the ETM. Then keep an eye on it as you tighten the clamp. Your original clamp should be fine.
- I don't know what a "metal string" is - but you don't need it if the pipe is seated correctly. You've got about a zero chance of seating it correctly and completely on the side of the road, by the way, it's a tight fit and a bit tricky the first few times that you seat that pipe. So, check your work all around after the clamp is snug to ensure that the pipe remained seated while you were tightening. Then tighten the intercooler end and you should be good.

Finally, make certain that your engine mounts are in good shape - if the engine is wiggling around in turns on split mounts, you'll be putting extra strain on the pipe.

You said that the original pipe had an oil leak by the intercooler? I don't understand what you mean by that...was it split? Did it have a crack in it? The pipe doesn't carry oil, so, the only way for oil to leak out is if there is a leak, and the oil from the PCV system is leaking out with the air under boost...

[2002V70XC]

Hi guys
Yes! This is on the ETM end!
I'll have to wait til the end of today to be able to try what Astro explained! I always thought once it popped in then it's in place but maybe not.
I'm not a mechanic but i'm lucky to have a little pen style mirror that came with my toolbox. I'll use that this time.
I'll post a photo about my metal string support!
Thanks all! Time to get public bus to work

[2002V70XC]

I managed to get a photo showing my current ETM with the pipe loose as well as the metal string support that I tried to use:

[Tahoe_XC]

I managed to get a photo showing my current ETM with the pipe loose as well as the metal string support that I tried to use:

From your 1st photo appears that it is not fully seated on the ETM.. Your not alone, this same problem (on my 01) was one of my first posts looking for insight... It happened right after I did my first PCV replacement. I now have done 3 (01, 04, & 06) the key is to get the hose to seat completely and uniformly and secure the hose clamp tight (from memory I believe it is 8mm socket)

[Antherzoll]

My suggestion, remove the OTE pipe to gain better access to the ETM from the front of the manifold and align the worm screw on the pipe clamp to face forward on the left (passenger side) of the ETM so you can tighten it with a small extention from the front of the manifold opposed to a long extension from the far side. Also while tightening make sure the other end of the pipe is loose and apply upwards pressure on the elbow going to the ETM with you hand. You will also want to check the positioning of the pipe clamp while tightening to make sure it's not maligned. Also get rid of the wire, it will only cut through the pipe in time.

[2002V70XC]

From your 1st photo appears that it is not fully seated on the ETM.. Your not alone, this same problem (on my 01) was one of my first posts looking for insight... It happened right after I did my first PCV replacement. I now have done 3 (01, 04, & 06) the key is to get the hose to seat completely and uniformly and secure the hose clamp tight (from memory I believe it is 8mm socket)

I haven't put the pipe back on thats why its still loose like that! I drove the car yesterday without knowing that the pipe got loose!! The difference was night and day in terms of performance.
I'll make sure that I get the pipe to seat properly this time and see if it would pop again.Thanks