Last week I began hearing an awful exhaust leak. Turns out the crossover pipe from the SAI pump to the engine blew up, split in half! I replaced it with 3/4 heater hose and all was fine for a couple of days. Now the fitting that attaches the hose to the pump has a hole blown in the back of it. Any ideas why this is happening? My SAI pump is loud, could that be the cause. Can I remove the crossover pipe and cap the metal line on the engine side?

 

Is there a reason you want to fudge it, and not just replace the broken part with an unbroken part?

 

Well replacing that poorly designed delicate hose with 3/4 heater hose is a good fix (currently have that setup on my 02 D2) and I have zero problems. I was lucky however and my special pump connection fitting was in good shape with about 3inches of the OEM straight tubing still intact so I slid the 3/4 heater hose up all the way to where the OEM line is pressed onto the OEM coupling. Zero issues with this setup.

Maybe your coupling was already brittle from the age/heat. You can buy another OEM line for 100-150.00 however DO NOT BUY A USED ONE as it will probably be near death as well.

 

Not trying the fudge it. I'm trying to find a temporary solution until I find out why it is blowing pipes. Right now it is just pumping exhaust fumes into the engine bay right below the AC intake.

I have found that the problem is that the SAI vacuum valves on the heads aren't closing. They are stuck open allowing exhaust gases to flow back in the crossover pipe to the pump. The heat causes the pipe to fail.

Pipe is currently removed and the engine side pipe is capped. No ill effects. So now I need to find new SAI valves or just remove it all!