How often should you need to top up the water in the charge cooler header tank?
Although I do check levels regulary, I’ve just had to put 1.5 litres of water in - second time its had to be topped up in tha last 6 months. I always thought with it being a sealed system it would never require topping up?!
…Also what anti freeze do people use?
It is a sealed system, so if you are topping it up at all you have a leak. If you can’t see the leak then the charger core in leaking on the inside and this is very bad as you could end up hydraulicing your engine. Get it checked out ASAP!!!
Have a good look at the seams on the charge cooler, look for discolouration or cracks in the welds, also take it off and look round the back and underneath, there should be no need to drain it to do that. As Sean says if there is nothing obvious get it checked with a pressure tester or similar.
Cheers Guys. I’ll have a look but not sure how obvious it will be as it can’t be a bad leak if it doesn’t need topping up often.
Not having much look with leaks - I have to top the coolant up too every other week as the jubilee clip of the front rad is leaking ever so slightly. Need to get both leaks sorted asap with winter coming!
Just had a another quick look, and I cant seem to see any obvous leaks.
I took the car to a meeting yesterday (90 mile round trip) after topping the water up, and the water level has not dropped.
Take the air hoses of each end and have a look inside. If it is leaking, it will only get worse and that could end very badly indeed.
Is yours an early pro alloy kit? I only ask as there have been a few reports on Lotustalk of their earlier kits failing (welds cracking) although I think they resolved this over time.
They now do a new design to fix the cracking problems, that is why I suggested taking it off they crack down the back on the lower seam 
Cheers Guys - another job for the weekend.
I guess it is an early kit from Proalloy - it would of been purchased between the beginning and middle of 2008.
Any ideas how much its it to replace just the the heat exchanger?
Just rang proalloy…
They suggested sending the unit down to them for it to be tested, but I don’t have the old intercooler to replace in the interim and I need the car at least 1-2 times a week.
So they have suggest taking it off and filling it with water to see if there is any obvious signs. Will give it ago this weekend.
I could send you my old intercooler for you to borrow?
Adrian - I may take you up on that kind offer, depends really on what Proalloy can do for me first. Will be ringing them Monday after I’ve taken it apart.
Or if I’m closer you can borrow mine, I’m in se London/Kent.
Adrian - I may take you up on that kind offer, depends really on what Proalloy can do for me first. Will be ringing them Monday after I’ve taken it apart.
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No problem just let me know and I’ll drop it in the post to you.
Cheers for the help guys. Still not had the charge cooler off yet, it probably won’t have time until next weekend now.
However, the water pump has now stopped working (not sure if this is related?!) Will give everything a good inspection at the weekend, but can anyone conform where the pump is located with the proalloy charge cooler system?
My original one is on the outlet pipe from the bottom of the header tank, but yours was fitted by the owner wasn’t it? So it could be anywhere? I suspect it is unlikely to be the bosch pump as they are generally very reliable, if you do need a new one they are a bosch PAD12V try ebay
Cheers Adrian
Yep, Craig fitted the chargecooler. I guessed it would be below the header tank as that where the wiring runs.
How much are they worth? Is this the right one…?
Yep that’s the one, I didn’t pay that much for my 2nd pump though, keep looking.
Also a good idea to have 2 anyway
or this one
Cheers mate will order that tonight.
I think you’re right - even if its okay, still good to keep a spare.