Hello all. I have a ballooned stock intercooler on my 07 GXP. I have the GMPP mod, which may have contributed to this problem as I understand it, after reading many posts on this forum. I don't see any cracks, just the top tube ballooned from about the middle to the driver's side end. When I get on the throttle, 16 psi is highest boost that I am seeing, and I hear what sounds sort of like a pressure cooker relief valve doing it's thing..."psst psst psst psst" (it seems like its coming from somewhere on the passenger side). I'm thinking that the intercooler likely does have a crack. I've checked and tightened all the hose clamps from the turbo to the intake manifold. I'm not throwing any codes. Is there a possibility that the intercooler and associated tubes are tight (i.e., no leaks), and that the noise is coming from somewhere else? I don't know much about how the wastegate operates, but could it be the culprit? Should I be able to move the wastegate rod by hand when the car is not running? (I can't.) Anyway, I thought I'd ask. I know there are some pretty sharp cookies in this forum. I've thought of disconnecting the hoses on the inlet and outlet of the intercooler and pressurizing it to check for pressure drop, but haven't done that yet. I'm thinking that some of you experts out there might suggest that I go ahead and replace the intercooler. Another question...if I had a ballooned intercooler with no leaks anywhere, no weird sounds or anything, could a ballooned intercooler by itself cause me to only realize 16 psi maximum boost (with the GMPP mod)? Just wondering...if the answer is "yes", then I won't feel as bad about making the plunge and ordering a new one, even if I'm still not sure if mine has a split/crack/busted seam. I've been looking at my options if I were to go ahead and order a new one, any suggestions there? I don't think I want an OEM, as I've read of solder issues with some of them, and also of issues with them ballooning on cars with the GMPP mod. I see that I can get the HAHN for around $600, but what about the other aftermarket brands, JJWorks, etc? How do the performance and quality compare among the aftermarket intercoolers? And how installation friendly are they...how much might I have to cut on the car's framework for proper fit? Thanks for reading, and thanks in advance for any insight and advice you might share!
Ballooned Intercooler Advice Request
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First, the boost pressure indicated is a function of air density. 26 pounds at sea level or close to it is equivalent to 22 at high altitude. The absolute number is highly variable
Read Flashes owner thread on air density and altitude.
Second, the ballooning IC I issue was a result of improperly assembled units from one production run. They are replaced under warranty for manufacturing defect. I suspect you can get a free replacement if you contact GM.
If you are not getting CEL for boost leak then it may not have progressed to that point. The sound you hear may be a cold air intake. Does your car have one?
Read Flashes owner thread on air density and altitude.
Second, the ballooning IC I issue was a result of improperly assembled units from one production run. They are replaced under warranty for manufacturing defect. I suspect you can get a free replacement if you contact GM.
If you are not getting CEL for boost leak then it may not have progressed to that point. The sound you hear may be a cold air intake. Does your car have one?
Thanks for your quick reply Rob! I'm in Charleston SC, so I'm pretty close to sea level. I bought my 2007 GXP new when they first came out back in Oct 2006 (57,000 miles ago), so I'm out of warranty...do you think GM might still do something for me? I don't have cold air intake...the GMMP mod is the only thing I've done to the car.
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If in fact the intercooler is ballooned then they should cover it. If the dealer denies the claim, contact GM directly.
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Hioslvr ;If you haven't had the IC out to see then on the passenger side end tank on the top is where the seam may have One or a couple small splits. Mine had a split about 3 1/2 in. long .Before I saw it everybody was telling me what to look for. Some said the cooler tubes Balloon out and others said look at the end tank on right side they have been spliting there on top .
I told the service writer at the Dealer what people said and when they brought it out It was split where they said . NOW theysaid it showed impack damage so they wouldn't cover it . But I did get it covered on my insurance from an accident I had on the way to Asheville NC in 2012. (3) days short of a Year . But GM should cover it even with the GMPP tune . Good luck with it. Oh mine is a March 2008 Build. Just replaced in June of 2013.
I told the service writer at the Dealer what people said and when they brought it out It was split where they said . NOW theysaid it showed impack damage so they wouldn't cover it . But I did get it covered on my insurance from an accident I had on the way to Asheville NC in 2012. (3) days short of a Year . But GM should cover it even with the GMPP tune . Good luck with it. Oh mine is a March 2008 Build. Just replaced in June of 2013.
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Just fixing a typo that Rob had here:
22 pounds at sea level or close to it is equivalent to 26 at high altitude.
As you go up in altitude, air density goes down. Therefore the ECM has command more boost to achieve the same effect at sea level.
As Rob suggested, check out this thread:
http://www.solsticeforum.com/forum/f43/boost-levels-atmospheric-conditions-thread-54423/
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To answer your question about different aftermarket IC's is as follows.
For your current setup either the HAHN or WERKS will do fine.
By the way if you do not want to spend money on a replacement I would contact the GM person here on the forum and have her pursue the matter with GM.
Is a defective IC and GM is aware there were some out there with this issue.
One suggestion stay away from the wastegate adjustment if no one has touched it before.
For your current setup either the HAHN or WERKS will do fine.
By the way if you do not want to spend money on a replacement I would contact the GM person here on the forum and have her pursue the matter with GM.
Is a defective IC and GM is aware there were some out there with this issue.
One suggestion stay away from the wastegate adjustment if no one has touched it before.
Well here's what my invoice said after taking it to the GM dealer...
54203 NEEDS INTERCOOLER, CALLED TECH HOTLINE TO SEE IF THERE WERE ANY KNOWN CASES, NO KNOWN CASES. 1157.00 PLUS TAX TOI INSTALL, CUSTOMER PAY PORTION WOULD BE 890.00 PLUS TAX
PLEASE PAY THIS AMOUNT 45.00
Any GM reps out there that might be able to help?
54203 NEEDS INTERCOOLER, CALLED TECH HOTLINE TO SEE IF THERE WERE ANY KNOWN CASES, NO KNOWN CASES. 1157.00 PLUS TAX TOI INSTALL, CUSTOMER PAY PORTION WOULD BE 890.00 PLUS TAX
PLEASE PAY THIS AMOUNT 45.00
Any GM reps out there that might be able to help?
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Damn the Pwerks intercooler starts at $575...
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If GM does not come to the rescue, I would definitely install an aftermarket IC.
Just pick from one of the supporting vendors here. Hahn, WERKS, DDM.
Just pick from one of the supporting vendors here. Hahn, WERKS, DDM.
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54203 NEEDS INTERCOOLER, CALLED TECH HOTLINE TO SEE IF THERE WERE ANY KNOWN CASES, NO KNOWN CASES. 1157.00 PLUS TAX TOI INSTALL, CUSTOMER PAY PORTION WOULD BE 890.00 PLUS TAX
Thats Bull Crap ! the Dealer told me if it didn't show impack damage it would be covered. There were lots of I/Cs replacedby GM . Ask them where they got the info ? If I hadn't got mine through the Ins.Co. I would have gotten a " Hahn " If anything it should be just a labor charge & not for the I/C itself. Contact the GM tech on the Forum they can help you find out whats happening . Good Luck
Thats Bull Crap ! the Dealer told me if it didn't show impack damage it would be covered. There were lots of I/Cs replacedby GM . Ask them where they got the info ? If I hadn't got mine through the Ins.Co. I would have gotten a " Hahn " If anything it should be just a labor charge & not for the I/C itself. Contact the GM tech on the Forum they can help you find out whats happening . Good Luck
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