Tag Archives: water line

What to Do When a Coolant Line Is Too Short

We have had questions of what to do if the OEM water lines are not long enough.  The short answer is to make a new water line.  It is simple to do and effective.  What you don’t want to do is to force your stock line to fit if it is not long enough.  In the worst case, it will crimp you line and prevent your turbo from being cooled correctly.

How do you make a new water line?

  1. Buy a length of antifreeze safe hose from your local auto part store.  Generally it is sold by the foot, and 12″ is plenty.  In our example, we used Gates 3/8″ fuel injection hose because it is the right diameter, and it works.
  2. Remove the old water line.
  3. Next determine how long to cut the new hose.  Put it in the engine bay and test fit the line.  Make it long enough such that the hose is not pinched and has a nice curve.  It doesn’t need to be too long such that it rubs against anything.
  4. Cut the hose to the correct length.
  5. Remove the sliver heat shielding off of the factory line.
  6. Put it on the newly cut line.
  7. Connect the new line with the heat shield onto the turbo and cylinder head.
  8. Ensure that the line is properly clamped on both ends.
  9. After starting the car for the first time, make sure there are no leaks.

Here is the finished product.  Note there are no kinks and we are reusing the OEM heat shielding.  We used common 3/8″ Gates fuel injector hose.

turbo water line
This is the finished product. We cut a new line that was approximately 2″ longer than the stock one. Note there are no kinks, and we are reusing the stock heat shielding from the OEM line.