leaking chargecooler?

hello guys

a couple of weeks ago, i finally finished the installation of the MMG chargecooler kit on my car.
i also have a 4-1 manifold and a sport cat from jim, and a 3,0" pulley. upgraded fuel pump and 440cc injectors
went to Komotec the 8th of may to adjust the remap and the car made 306hp on the dyno on a hot day

was at Spa yesterday with MLR
great day but couldn’t drive the car, the car was so slow, like missing 70/80bhp, i was 30 km/h slower at Les Combes and 10/12 sec slower than my last trip mid march (car made 2’55" , without chargecooler)

the car doesn’t pull hard as it used to, the 5th gear was useless yesterday

i noticed the loss of power few days ago, and i also did noticed this trace of oil, near the spark plugs cover

i thought it was the valve cover gasket that was leaky
but yesterday, i notice my rear window and below was covered by traces of oil.

had a close look of the chargecooler and notice some small cracks on the weldings (no pictures yet)
got no MIL, airfilter looks ok, not clogged

where could this oil come from?
could it be that my chargecooler is leaky?
it is 3 weeks old and was driven less than 1000km…

will swap back the stock IC to see if i notice an improvement

Do you have air con?

yes

but system is still empty, didn’t refill it yet

I had 2 charge coolers split in quick succession along a fold.

Same symptoms as you.

Proalloy made me up a new one with curved edges (no folds in metalwork) and has been fine eversince.

Consensus was the frequency of vibration at high revs was just right to cause the failure.

Latest version below:


Ex77

I only ask as I hadn’t capped the pipes coming out of the sill when mine was taken out and strangely that’s where the fluid (or what was left of it) would end up after a TD, all the way up there!

@Ex77: i don’t have the same kind of CC
do you have a picture of your system installed?, would like to see how it looks as i never saw this CC set up on a car

mine looks like this (not my car but same CC)

My CC sits in the right wing just above the wheel arch liner.

It’s neat and out of the way. It’s difficult to photograph but it’s under where the word “Exige” is written in yellow.

My cracks were small and difficult to see and only opened up when CC was presurised.

Ex77

This does seem to happen on some charge coolers, not sure why it does happen, the oil is probably where there is small amounts of oil getting blown out through the crack along with the compressed air. I can see this making the 80hp loss you are seeing as the more boost the large the hole becomes are the case is puffing out like a set of bellows :frowning:

That would be a pity as those MMG C/Cs are really nice.
Hope you round up those ponies.

picture of the cracks along the welding

Certainly looks like other I have seen before, I think this is the reason why the proalloy ones are now stepped so they don’t act like bellows

Real shame It’s failed ,but,r+d never stops …as Frank would vouch for …
I’m sure Liam will gladly have it back and make it forever better …

Yeah, as has been said the oil wont be from the charge cooler itself as a charge cooler circuit doesn’t have any oil in it.

It looks like you have two problems. 1. an excessively breathing engine and 2. a hole in your charge cooler where the breathed oil is escaping.

To be fair if you have a split in your charge cooler and all of your charge air is escaping then this will account for your power loss. The breathed oil also needs looking at as yours does look excessive.

Maybe worth looking at some oil catch cans.

Ex77

i have oil catch cans, but never got time to install them…
my fault, as it takes 20 minutes
was waiting to be sure my mods were working well before fitting extra stuff messing with engine bay clearance

anyway, i contacted Radtec this morning and they replied within the hour
they are making me a new chargecooler

Its a typical case of ‘modders blight’ i fear :confused:

Why don’t you guys use proper charge coolers ? I’ve never had an issue in six years.

send me one uncle frank :smiley:

some news:

i’m still waiting an update from Radtec,
got no news for the last 2 weeks and i’m starting to be pretty pissed off!!
i was told 2 weeks lead time to get a new CC when i informed them about the problem at the end of may
i’m missing track days and i’m still not sure if i’ll be able to go to Le Mans on the 4th of august

very disappointed in Radtec!

[quote=SeanB]Yeah, as has been said the oil wont be from the charge cooler itself as a charge cooler circuit doesn’t have any oil in it.

It looks like you have two problems. 1. an excessively breathing engine and 2. a hole in your charge cooler where the breathed oil is escaping.

To be fair if you have a split in your charge cooler and all of your charge air is escaping then this will account for your power loss. The breathed oil also needs looking at as yours does look excessive.[/quote]
My concern would be the breathed oil too