Hole in my Intercooler!!!!!!!

[Dpicariello]

Evening,

Just had my front bumper off (with help from Tristan (Merlin's S4)) as I wanted to take a look at everything behind it.
No major probs until we did a pressure test. Heard a major air leak coming from the intercooler. I've noticed when i've been under the car that at some point the intercooler has impacted with the crank pulley. Not ideal I know but this is where the air is literally gushing out. See picture below.



First question.
Is it possible to get this repaired? I know that Jamo had MRC repair his but I read that this was just a pinhole.

Second Question.
If it's not repairable, does anyone have an S2 intercooler they would want to sell me?

Third Question.
Would it be wise to upgrade to a RS2 intercooler? Does anyone have one of these for sale and the accompanying cross member? Or am I asking the million dollar question here?

Many thanks.
Dan

[Jamo]

Yikes you engine has hit the intercooler, look at the circle identation in the core.

You can have the intercooler recored or probably cheaper to buy a 2nd hand S2 IC

My IC hole was not in the core but in the end tank.

[Rusty]

Not ideal mate ! Secondhand S2 ICs come up now and again and are usually 'quite' cheap. Fitting an IC is very simple and you can fit the infamous Mark H mod to the outlet to sure thigs up somewhat!

RS2 one would be a good upgrade but an RS2 XM is a rare beast! New parts are going to be £500+ easily.

An RS2 IC is £324.18+vat from VAGParts.

I see that the RS2 airbox has been added. A snip at £195+vat!

You can have the existing S2 XM modified to take the RS2 item, I might be wrong but I think taht Greg_S did this?

Had your car been cutting out on full boost, i.e. the overboost protection was cutting in? If not then it should have!

Good luck mate. Hope you get it sorted.

[s2_bo]

Wow! and you still maneged to get 290+ BHP with that? must be a nice map on your car - Ill have a S2 IC you can have soon, - need to fit my new one first though.

Otherwise i also know that Andy form Plymouth upgraded his to RS2 not so long ago so he might still have the 3b one dotting about?
HTH.
Bo

[terrybullwon]

A very cleaver welder might help you out?
But either way the ic needs to come off to be looked at properly.
Strange how thats happend, is there any damage on your bumper?

I have a 3b ic & Xmemebr

Also a Aby ic & Xmember

And just because i can a RS2 ic & Xmember

I am sorry though the The 1st two are SOLD and the RS2 is going on my car

Sorry

[newsh]

I've got a 3b IC around somewhere but IIRC its smaller than the ABY one?

[Jamo]

I've seen that before on a few S2's, Change the snub mount on the car and check the engine mounts.

[philS2]

mine had done exactly the same.it seems as though the engine has lurched forward and down.i don't think it was the intercooler hitting the pulley as it seemed real solid. my engine mounts were shot,as the sump was shiny where it had been rubbing on the subframe so i renewed those.don't know if it's cured it,i haven't been under there for a while.

[Jamo]

I've got a 3b IC around somewhere but IIRC its smaller than the ABY one?

Aye it is.

For the money of the RS2IC it's worth buying the IC that Bo has bought and MartinJS started the trend with.

[Dpicariello]

Yikes you engine has hit the intercooler, look at the circle identation in the core.

I know, I noticed that the first time I was under the car last summer but ony just realised that it's actually done some proper damage in peircing the IC.

Wow! and you still maneged to get 290+ BHP with that? must be a nice map on your car

I keep finding air leaks on this car! Definitely getting it back on the rollers when all this is sorted.

Thanks to everyone for the PM's. I'm tempted by an upgrade though. Bo, is what you are doing possible on mine?

[Dpicariello]

I've seen that before on a few S2's, Change the snub mount on the car and check the engine mounts.

I'm gonna check my mounts then. I always thought that the car had a bump at some point and that had just never been changed.

Where's the snub mount? I'm guessing it's that rubber covered stub on the right above the crank pulley (as you look up from below).

[twoqu]

It is possible to repair. Places like Serck use a resin that seals it up. It was @£50 a few years back. Obviously if you can get an undamaged replacement for similiar money, better to go that route!

[s2_bo]

Thanks to everyone for the PM's. I'm tempted by an upgrade though. Bo, is what you are doing possible on mine?

Of course it is . Its not OEP though, not one bit in fact. Im just sourcing the Stainless steel bends and pipe as well as Silicon hoses to join to intercooler.

Will let you know how i get on.

Cheers.
Bo

[Jamo]

I'm gonna check my mounts then. I always thought that the car had a bump at some point and that had just never been changed.

Where's the snub mount? I'm guessing it's that rubber covered stub on the right above the crank pulley (as you look up from below).

Yes it is, if it's worn it allows more engine movement foward and back.

You can upgrade it ( On my to-do list ) ala this thread

http://www.s2forum.com/forum/showthread.php?t=4799

034 also sell an upgrade version via Corey.