Cracked intercooler shroud - LotusTalk

300hpMR2 · 11-27-2008, 01:50 PM

I did a search but didn't come across a similar post. Anyhow, I was installing my RLS IC pipes the other day and noticed that the top corners of my plastic OEM intercooler shroud are cracked. Probably due to excessive engine movement? Anyone else have this happen?

Noel · 11-27-2008, 04:02 PM

I'm surprised it hasn't come up. It's a fairly common part failure and has been replaced FOC under warranty for my cases.

You guessed it, excessive engine movement especially under and off load either causes it to crack like how you see it or causes the front piece with the oval clamps to fall off.

I had 2 replaced under warranty, one at 3000KMs, one at 9000KMs. I no longer use this part as I've upgraded my OEM intercooler.

300hpMR2 · 11-27-2008, 11:22 PM

Quote:

Originally Posted by Noel

I'm surprised it hasn't come up. It's a fairly common part failure and has been replaced FOC under warranty for my cases.

You guessed it, excessive engine movement especially under and off load either causes it to crack like how you see it or causes the front piece with the oval clamps to fall off.

I had 2 replaced under warranty, one at 3000KMs, one at 9000KMs. I no longer use this part as I've upgraded my OEM intercooler.

I guess I'll install my polyurethane engine mount inserts before considering a cf ic shroud.

Did you upgrade to an air/water setup? An RLS air/air IC would still use the shroud, right?

Noel · 11-28-2008, 05:17 AM

Yes, I'm using a water to air chargecooler.

Apologies, NFI on RLS setup.

Won't go with an even more rigid CF setup. It if doesn't crack, it'd make the next piece connecting to the main roof duct constantly fall off.

Our local dealership even pop riveted the OEM plastic shroud to the air to air intercooler to make it move less. That still resulted in cracks over a very short time. And if pop riveting ain't gonna work, CF won't either.

Thomasio · 11-28-2008, 12:07 PM

Yep, RLS intercooler uses same shroud or our CF shroud. There is a ton of engine movement back there, the urethane mount stiffeners (sold on another thread) help out a lot.

def · 11-28-2008, 12:35 PM

It's amazing how many problems keep coming up due to engine movement. Glad I've installed my engine mount inserts even on an elise

shay2nak · 11-28-2008, 09:25 PM

haven't seen this problem before, but I just put in a new RLS IC and new IC shroud plus the engine mounts. So I guess I won't be seeing the problem anyway.

300hpMR2 · 11-28-2008, 11:01 PM

So I guess even more reason to upgrade the engine mounts either with inserts or upgraded mounts.

alexscotti · 11-29-2008, 05:53 AM

huh, my shroud is cracked too. rigid cf seems like the wrong direction to be going in here. why didn't they make this thing out of rubber?

qball · 11-29-2008, 07:05 AM

Quote:

Originally Posted by 300hpMR2

So I guess even more reason to upgrade the engine mounts either with inserts or upgraded mounts.

Well the upgraded mounts will cause some more vibration, but less engine flex... not sure if that will help or worsen this particular situation...

300hpMR2 · 11-29-2008, 07:50 AM

It'd be great if there could be a silicone hump hose version of the shroud but that would be cost prohibitive.

agirls · 06-06-2009, 01:12 PM

Ah, I was gonna start a thread, glad I searched first!

I noticed all of the corners on my shroud were cracked and pointed it out to the service advisor at my dealership. I figured all they had to do was to replace the plastic piece. When I picked up the car (it was there for another reason) he told me they would have to replace the whole intercooler! After that, I felt like an a****** for pointing out a little crack. But, if it's a problem and others have had it replaced, I guess I don't feel as bad. I'm waiting for Lotus to approve it under warranty. I guess it's time to research the engine mount upgrades.

Thomasio · 06-06-2009, 01:19 PM

They are easy enough to fix with ABS-plastic-repair 2-part epoxy.

The cracks aren't going to harm airflow.

agirls · 06-06-2009, 01:32 PM

So, another words, I am being an ass for pointing is out, lol. Well, if they replace it under warrantly, then it'll be replaced. If not, then I'll fill it in.

Thomasio · 06-06-2009, 02:06 PM

Quote:

Originally Posted by agirls

So, another words, I am being an ass for pointing is out, lol. Well, if they replace it under warrantly, then it'll be replaced. If not, then I'll fill it in.

It's good that you noticed it... it does mean that your engine is flopping around quite a bit. Might want to get the urethane mount inserts or mount kit.

Noel · 06-06-2009, 05:08 PM

All supercharged Exige with this intercooler has this problem. Yes, it's attributed to too much engine flex/movement/vibration.

I don't see how they should or need to replace the whole intercooler, only the cracked piece is replaced. But if they're so dumb, that's not your issue.

Sh4rkattk · 06-06-2009, 05:41 PM

Anyone experience a cracked intercooler duct? #11 Snaped off after the two front tabs.

agirls · 06-06-2009, 10:20 PM

Quote:

Originally Posted by Noel

All supercharged Exige with this intercooler has this problem. Yes, it's attributed to too much engine flex/movement/vibration.

I don't see how they should or need to replace the whole intercooler, only the cracked piece is replaced. But if they're so dumb, that's not your issue.

My guess would be that the service advisor misunderstood the mechanic. The mechanic was out on a test drive. Whenever there is an issue, he usually comes out and talks. Anyhow, it'll be sorted out and this is my sign that I need to start upgrading the weaker points of the car.

apk919 · 06-07-2009, 04:24 AM

Quote:

Originally Posted by Sh4rkattk

Anyone experience a cracked intercooler duct? #11 Snaped off after the two front tabs.

Yup... didn't snap off completely, but I had cracks on both sides. Repaired with plastic cement. If you hear a clicking sound behind your head when releasing the clutch or going to throttle, it's a good thing to check. No problems since upgrading my engine mounts.

Composites · 06-08-2009, 08:30 AM

Anyone broken one of the carbon fiber ones we've made? There's at least 30of them out there already.

11-27-2008, 01:50 PM	#1 (permalink)
300hpMR2 Not a poseur anymore! Join Date: Jul 2007 Location: Orange County, CA Posts: 578	Cracked intercooler shroud I did a search but didn't come across a similar post. Anyhow, I was installing my RLS IC pipes the other day and noticed that the top corners of my plastic OEM intercooler shroud are cracked. Probably due to excessive engine movement? Anyone else have this happen? Attached Images __________________ 07 Phantom Black Exige S - Touring Pack/Track Pack/TC/SS/Titan QR rack/Costco wireless rear view cam/BWR door sill protectors/Locking gas cap mod/headlight film with bubbles/Larini SC Sport/Multivex mirrors/Saikou Michi Oil Catch Cans/Dunlop Direzza Z1 Star Specs/Manly's Motor Mounts

11-28-2008, 12:07 PM	#5 (permalink)
Thomasio really light stuff Join Date: Jul 2003 Posts: 3,503	Yep, RLS intercooler uses same shroud or our CF shroud. There is a ton of engine movement back there, the urethane mount stiffeners (sold on another thread) help out a lot. __________________ 07 SY Exige S Really Light Stuff Intercooler . RLS Tubes . RLS Water/Methanol Injection . RLS 3.0" Pulley . RLS Wing Plates . RLS CF Window Panel

11-28-2008, 12:35 PM	#6 (permalink)
def ...ault Join Date: Jul 2005 Location: Mountain View, CA Posts: 2,610	It's amazing how many problems keep coming up due to engine movement. Glad I've installed my engine mount inserts even on an elise __________________ //kevin - 05 Graphite Gray - Red Touring / LSS / Starshield / Stage 2 + more SOLD after 1192 days and 22961 miles

11-28-2008, 09:25 PM	#7 (permalink)
shay2nak I <3 chicken, I <3 liver Join Date: Dec 2003 Location: Land of da 1000 Oaks, CA Posts: 15,056	haven't seen this problem before, but I just put in a new RLS IC and new IC shroud plus the engine mounts. So I guess I won't be seeing the problem anyway. __________________ save ~10 lbs gain 1 hp EQ: Y=(190X) / (1984-X) where Y is (HP) and X is (lbs) '07 EXIGE S * MY CAR ** VIDEOS! '08 ACURA TSX 6-speed http://www.makeNYNYagain.com

11-28-2008, 11:01 PM	#8 (permalink)
300hpMR2 Not a poseur anymore! Join Date: Jul 2007 Location: Orange County, CA Posts: 578	So I guess even more reason to upgrade the engine mounts either with inserts or upgraded mounts. __________________ 07 Phantom Black Exige S - Touring Pack/Track Pack/TC/SS/Titan QR rack/Costco wireless rear view cam/BWR door sill protectors/Locking gas cap mod/headlight film with bubbles/Larini SC Sport/Multivex mirrors/Saikou Michi Oil Catch Cans/Dunlop Direzza Z1 Star Specs/Manly's Motor Mounts

11-27-2008, 04:02 PM	#2 (permalink)
Noel Exige Cup 255 Join Date: Apr 2007 Location: 33.87°S 151.21°E Car: ロータス MKII エキシージ Type: Komo-Tec S300 Posts: 329	I'm surprised it hasn't come up. It's a fairly common part failure and has been replaced FOC under warranty for my cases. You guessed it, excessive engine movement especially under and off load either causes it to crack like how you see it or causes the front piece with the oval clamps to fall off. I had 2 replaced under warranty, one at 3000KMs, one at 9000KMs. I no longer use this part as I've upgraded my OEM intercooler.

11-28-2008, 05:17 AM	#4 (permalink)
Noel Exige Cup 255 Join Date: Apr 2007 Location: 33.87°S 151.21°E Car: ロータス MKII エキシージ Type: Komo-Tec S300 Posts: 329	Yes, I'm using a water to air chargecooler. Apologies, NFI on RLS setup. Won't go with an even more rigid CF setup. It if doesn't crack, it'd make the next piece connecting to the main roof duct constantly fall off. Our local dealership even pop riveted the OEM plastic shroud to the air to air intercooler to make it move less. That still resulted in cracks over a very short time. And if pop riveting ain't gonna work, CF won't either.

11-29-2008, 05:53 AM	#9 (permalink)
alexscotti Registered User Join Date: Oct 2006 Posts: 88 Images: 1	huh, my shroud is cracked too. rigid cf seems like the wrong direction to be going in here. why didn't they make this thing out of rubber?

11-29-2008, 07:50 AM	#11 (permalink)
300hpMR2 Not a poseur anymore! Join Date: Jul 2007 Location: Orange County, CA Posts: 578	It'd be great if there could be a silicone hump hose version of the shroud but that would be cost prohibitive. __________________ 07 Phantom Black Exige S - Touring Pack/Track Pack/TC/SS/Titan QR rack/Costco wireless rear view cam/BWR door sill protectors/Locking gas cap mod/headlight film with bubbles/Larini SC Sport/Multivex mirrors/Saikou Michi Oil Catch Cans/Dunlop Direzza Z1 Star Specs/Manly's Motor Mounts

06-06-2009, 01:12 PM	#12 (permalink)
agirls Registered User Join Date: Mar 2008 Location: Santa Paula, CA Posts: 771 Images: 73	Ah, I was gonna start a thread, glad I searched first! I noticed all of the corners on my shroud were cracked and pointed it out to the service advisor at my dealership. I figured all they had to do was to replace the plastic piece. When I picked up the car (it was there for another reason) he told me they would have to replace the whole intercooler! After that, I felt like an a****** for pointing out a little crack. But, if it's a problem and others have had it replaced, I guess I don't feel as bad. I'm waiting for Lotus to approve it under warranty. I guess it's time to research the engine mount upgrades. Attached Images __________________ Toys- 07 Lotus Exige S Chrome Orange 05 Ducati S4R 02 Suzuki SV650 09 Kawasaki KLX250

06-06-2009, 01:19 PM	#13 (permalink)
Thomasio really light stuff Join Date: Jul 2003 Posts: 3,503	They are easy enough to fix with ABS-plastic-repair 2-part epoxy. The cracks aren't going to harm airflow. __________________ 07 SY Exige S Really Light Stuff Intercooler . RLS Tubes . RLS Water/Methanol Injection . RLS 3.0" Pulley . RLS Wing Plates . RLS CF Window Panel

06-06-2009, 01:32 PM	#14 (permalink)
agirls Registered User Join Date: Mar 2008 Location: Santa Paula, CA Posts: 771 Images: 73	So, another words, I am being an ass for pointing is out, lol. Well, if they replace it under warrantly, then it'll be replaced. If not, then I'll fill it in. __________________ Toys- 07 Lotus Exige S Chrome Orange 05 Ducati S4R 02 Suzuki SV650 09 Kawasaki KLX250

06-06-2009, 05:08 PM	#16 (permalink)
Noel Exige Cup 255 Join Date: Apr 2007 Location: 33.87°S 151.21°E Car: ロータス MKII エキシージ Type: Komo-Tec S300 Posts: 329	All supercharged Exige with this intercooler has this problem. Yes, it's attributed to too much engine flex/movement/vibration. I don't see how they should or need to replace the whole intercooler, only the cracked piece is replaced. But if they're so dumb, that's not your issue.

06-06-2009, 05:41 PM	#17 (permalink)
Sh4rkattk A pound at a time. Join Date: Nov 2007 Location: LA SFV Posts: 559	Anyone experience a cracked intercooler duct? #11 Snaped off after the two front tabs. __________________ 07 Exige S - PhB., TP, TP, LSD, S111 Rear Panel Delete, 2Bular De-Cat, 2Bular 8x24 Burnt GT3, Custom AEM Intake, 6k HID's, Schroth 4pt ASM Harnesses, Milled Steering Arms, Bronze Volk TE37 w/ RE-01R's, Carbon Craftsquare Mirrors, Carbon Front Lip, Benetec Dry Carbon Undertray/Diffuser

06-08-2009, 08:30 AM	#20 (permalink)
Composites Carbon Guru Join Date: Nov 2006 Location: Glendale, WI USA Posts: 239	Anyone broken one of the carbon fiber ones we've made? There's at least 30of them out there already. __________________ Mike Cudahy President Prototype Composites (414) 354-5144

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