URGENT - Massive/Sudden Coolant Leak - Possible Service Bulletin

[Hiroprotaganist]

All -
Was driving last evening in my car doing my weekly Friday evening cathartic drive after the wife and kids have gone to sleep. After all the hot weather we've had in DC area - last evening was just lovely with low humidity and cooler temperatures.

Was moving along VERY slowly about about 50mph in 6th gear when I noticed the engine temp go from 195 to 215 to 238 in less than about 1 minute. The entire evening I had been taking it easy (I mean really easy, I was just happy listening to some good music) so I knew there was no normal reason for this.

I also noticed a metallic "clanging" sound coming from what sounded like underneath the transmission - although it was hard to tell the exact location. Pulled off Clara Barton Parkway and was able to find a quiet parking lot - car REALLY started smoking badly so I just shut it down. Looked under the car and coolant was coming down like rain. To make a long story short, left car in DC for the evening (it was then 2am and a safe area - near Sibley Hospital if you're familiar) and got a ride home (my father-in-law rocks!). Called the local dealer at 8am and arranged for a flatbed - got it taken immediately over there and they're now getting it fixed. Was also informed by dealer that this exact scenario just occurred with another client's car earlier this week and that they had just received a bulletin from Lotus on this.

So - if you're going far from home, make sure you're prepared for this eventuality. I didn't get wink of sleep......Seriously, it all happened in a matter of 1-2 minutes so really be watching those temps...

[PhlypSide]

Oh my. AAA and a Flatbed home!

Sorry to hear about this, but thank you for sharing. Is this an "S" specific issue only? Or do you think even us NA folks need to worry?

[Hiroprotaganist]

Originally Posted by PhlypSide

Oh my. AAA and a Flatbed home!

Sorry to hear about this, but thank you for sharing. Is this an "S" specific issue only? Or do you think even us NA folks need to worry?

Unfortunately, I didn't get that piece of (very relevant) information. I was just too exhausted to really zero in on the issue - it was more of a relief than anything just to have the car off the street and at the dealer.

The really funny thing I noticed at 1:30am in the morning was the preponderance of single men in Porsches driving around that hour where I was stranded - I suspect they were also fathers like myself doing the quiet solo evening run.....

[PhlypSide]

Well I'm glad you caught the issue and shut her down almost immediately If you're ever in Chicago over a weekend, we all go driving on Saturday nights (also late at night LOL!) and we also have a few Porsche members as well.

Keep us posted and I hope that your car is back on the road again soon, I'm sure the Touareg and Jetta are nice, but I'm also quite sure they don't compare!

[Lotusmotion]

What exactly was the source of the problem...know yet?

[Chris Mackey]

How many miles on the car? Are you using the factory coolant? Are there any mods to the car?

[creafish]

Originally Posted by PhlypSide

Well I'm glad you caught the issue and shut her down almost immediately If you're ever in Chicago over a weekend, we all go driving on Saturday nights (also late at night LOL!) and we also have a few Porsche members as well.

Keep us posted and I hope that your car is back on the road again soon, I'm sure the Touareg and Jetta are nice, but I'm also quite sure they don't compare!

I'm in Chicago. When do you go driving? I'm near LSD Near bryn Mawer

[Hiroprotaganist]

Originally Posted by Chris Mackey

How many miles on the car? Are you using the factory coolant? Are there any mods to the car?

About 1200 miles - absolutely NO mods. Car went through 1000 mile service about 2 weeks ago with flying colors. Break in was completely proper and by the book.

Dealer brought her into the shop late today - will know more next week. For now, am stuck with TDi power!

[ace10]

was it apparent from where the coolant was leaking? ie front of car versus rear.

also, do you happen to know the build date for your car? i have been considering starting an S thread related to the radiator. i've noticed that some have a silver one and others have black, and was wondering why there was a running change. i suspect supply issues, but i'd like to gather some data and see if it can be correlated to any actual cooling issue with the S.

best of luck with the car. hopefully no damage done with that operating temp and hopefully the metal "clanging" was just an unhappy starving water pump and not engine internals. make sure that place in maryland goes over your car with a fine tooth comb for possible coolant-related issues.

[Hiroprotaganist]

Originally Posted by ace10

was it apparent from where the coolant was leaking? ie front of car versus rear.

also, do you happen to know the build date for your car? i have been considering starting an S thread related to the radiator. i've noticed that some have a silver one and others have black, and was wondering why there was a running change. i suspect supply issues, but i'd like to gather some data and see if it can be correlated to any actual cooling issue with the S.

best of luck with the car. hopefully no damage done with that operating temp and hopefully the metal "clanging" was just an unhappy starving water pump and not engine internals. make sure that place in maryland goes over your car with a fine tooth comb for possible coolant-related issues.

Thak you all. I will find out the build date - it was rather late in the year as I have the "bumperettes" - I took delivery in late May and I believe the build was in March/April.

The coolant leak was definitely coming from the front - and the "clanging" I truly believe NOT to be related to the engine itself. I shut it down fast enough and don't think I have issues related to overheating.

The radiator assembly is black if that helps. I'm going to request that they perform a compression check just to make sure....

[lotus54]

I had a slow coolant leak on my '05 Elise. It was the radiator hose, slightly loose clamp.
This has been discussed here before.
But what you describe seems different.

I'd like to see the bulletin notice. Since I live a long way from any dealer, it might be something I should have them look into.

Mark

[jhnmdahl]

So we still don't know what leaked, or whether there's a TSB?

[Patricko]

Originally Posted by Hiroprotaganist

So - if you're going far from home, make sure you're prepared for this eventuality. I didn't get wink of sleep......Seriously, it all happened in a matter of 1-2 minutes so really be watching those temps...

A few hundred people just drove thousands of miles to LOG27 in Aspen and back without any problems that I have heard of. Shinoo (Exige), Charile (Exige S) and I (Exige) did right around 2,000 miles without any issues.

I don't think this is a widespread issue.

[Patricko]

Originally Posted by Hiroprotaganist

Was moving along VERY slowly about about 50mph in 6th gear when I noticed the engine temp go from 195 to 215 to 238 in less than about 1 minute. The entire evening I had been taking it easy (I mean really easy, I was just happy listening to some good music) so I knew there was no normal reason for this.

50mph in 6th gear is too slow for that gear. You will have been laboring the engine, this may have contributed to your problem and the owners manual specifically says not to do it. I try to keep the RPMs at a minimum of 4k at all times.

2006 Exige Owners Manual

Page 73

Do not allow the engine to labour in too high a gear ratio, but change down and let the engine operate in its natural power band.

[Patricko]

You will have been at a bit less than 2600 RPM (50mph in 6th gear) and that will have been hard on the engine...

I am not saying you did not have a problem but you should change your driving style.

[jkolb]

I have one of the last S cars produced before the bumperettes. Black radiator. Drove 2,500 miles round trip to LOG 27 and back with typical open road temp of 183 regardless of ambient temp. Nonetheless, I would be very interested in finding out the source of this problem as I am 160 miles from the nearest dealer. TIA for future updates.

Jerry

[necro]

Originally Posted by Patricko

You will have been at a bit less than 2600 RPM (50mph in 6th gear) and that will have been hard on the engine...

So what is the recommended RPM range?

I must have missed that little part.

[pianomaniac]

Originally Posted by necro

So what is the recommended RPM range?

I must have missed that little part.

These little engines like to have the revs up. Like Patrick said,4K is about as low as you want to keep the revs. I rarely use 6th gear,even on the freeway unless I'm 100+mph. (which of course, I never do

[wildwhl]

Paricko -

I can appreciate your comment on lugging the engine, but if you're just cruising around (i.e. little to no load) I don't see the specific concern, though your point is well taken. Even so, I doubt lugging at that RPM range will cause any issues other than getting your ass run over for lack of acceleration. Of course, in my case, things sound so much better (2bular) over 4K I keep it there anyway

WW

[Needspeed]

Originally Posted by ace10

was it apparent from where the coolant was leaking? ie front of car versus rear.

also, do you happen to know the build date for your car? i have been considering starting an S thread related to the radiator. i've noticed that some have a silver one and others have black, and was wondering why there was a running change. i suspect supply issues, but i'd like to gather some data and see if it can be correlated to any actual cooling issue with the S.

best of luck with the car. hopefully no damage done with that operating temp and hopefully the metal "clanging" was just an unhappy starving water pump and not engine internals. make sure that place in maryland goes over your car with a fine tooth comb for possible coolant-related issues.

I asked Robert at HRM the radiator color question last year and I think he said it is just a different supplier of radiators. It just happens to be who the factory got their radiators from that week. No big deal in the scheme of things. I have a black one on my S and I think I like it better than silver because it is less noticeable.