Anyone ever had the plastiic inlet side of the intercooler break? I was going down the road and heard a slight pop and the check engine light came on. I pulled over and the car died and was hard to start. When it got started I had to keep reving the engine to keep it running. I could hear the turbo spool up louder than normal so I figured the problem was turbo related. I was able to get it running and keep it running so limped it home. Engine temp was fine and I could get it up to 60 but had absolutly no power and no boost.

By the time I got home I guess the computer had adjusted and it would idle and not die. With it running I lifted the hood and could hear a leak close to the front of the car and thought maybe a intercooler connection had come apart. I couldn't really tell from the top so I jacked it up and pulled the cover below the intercooler off. Both inlet and outlet hoses were fine. Started it back up and could still hear the leak. As I was checking the inlet side of the intercooler I noticed it was cracked and the crack was about 1/8" wide.

I'm going to take it to the dealer in the morning but thought while I had the cover off figured I could duct tape the crack and maybe that would help get it there in the morning. That lasted all of about 1 minute before the pressure blew it off. I am afraid they won't cover it under warrantee. A couple of reasons, I pulled the cover off and messed with it. The Tape left sticky residue on the intercooler and mostly about 3 months ago I ran over something on the road that made a blemish in the lowest part of the bumper and cracked the cover that is under the intercooler. It has ran fine for 3 months since then so I doubt that had anything to do with the inlet cracking.

Has anyone else had this happen? If so what was the outcome? If they won't cover it then I'd have a good excuse to get a larger aftermarket unit but I really don't need to be out $700.

Thanks,

Russ

 

Unless there is some direct damage it should be covered.

I broke mine when I got run off the road and the other guys insurance covered it. The cooler held up well but the plastic on botgh ends broke off.

No way the tape would have held up but even that should not hurt you warranty other than the guys in the service department saying hey look at this.

The cooler on mine was $375.00 if I recall and what ever labor. Now also keep in mind if it was road damage you should be over your deductable.

 

Yes, this is a common issue, and several board members have reported this issue (including me). The replacement part is in short supply, and so you may be in a loaner while they wait on parts.

 

Looks like a good reason to buy the Hahn IC and the pipes. I was going to go for the pipes only first, but this post changed my mind on that idea.

 

I'd love to have the Hahn IC and Pipe kit. I've drag raced for 25 years but sold my 67 Camaro and all racing equipment about 9 months ago. I thought I was through buying performance parts for a while :-)

 

Ford Diesel trucks have the same problem. I will be po'd if it happens to mine.

 

i wanna say i was the first with this problem on the board. got my kit coming and will probably get a hard pipe kit for the wifes car.

 

Mighty Mouse did yours just pop and crack. Mine is cracked across the back side of the inlet then runs across the top of the neck where the inlet hose connects. I can't see the crack on the tipside by the inlet but it feels like it may have cracked along a casting line. Why they don't make these or our radiator end caps out of metal is beyond me.

Thanks,

Russ

 

Also...

Metal isn't automatically a better material to use. In this case, there are design issues with the part itself. Designed properly, non-metal materials can certainly hold their own.

 

mine was leaking at the sensor on the lower ic pipe.