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Issue after intercooler install, car revs high then drops way low

So that connection goes inside the housing? Maybe that's where the leak is. That would explain how it leaks only when installed.

g2g on plane heading home.

Jeff
 


OK I fixed the hoses going into the housing. They no longer go into it.

Would it be a bad idea to install the core and not fill it with coolant and do a test drive?
 
I think that will be fine. When the coolant is in it it is not under pressure like a radiator is and if it was then the vacuum on the core would cause greater force than without.

Jeff
 
Installed the IC again today. Ran the car with no coolant in the IC. Low and behold WHITE SMOKE came out of the exhaust. What...how...grr.

Both the coolant holes on the lim are blocked off. What is causing the coolant to get into the engine when the IC is installed but no coolant in the engine with just the sc on?
 


So when you pull it down you don't touch the LIM right? Did you use Pipe dope or Teflon tape on the block offs for the TB? Do they sit below flush? when you removed the SC was there coolant where the TB is? My only thought is that with the IC in place the holes are lined up with the block off hex screws and if they are not below flush they may be pushing on the IC adapter and making it harder to seal but the block off seal screws would have to leak. Use your vacuum pump and one of the cups to pull a vacuum on each of the block offs. Other than that I'm out of ideas right now.

Jeff
 
That is correct i do not mess with the lim, only clean the surface of it. i used teflon tape on the tap screws. They sit below flush. Ill pull the sc off tomorrow and look for any coolant. I havent noticed any coolant around the screws on my previous tries. I will pull a vacuum on each of them tomorrow as well.

Anyone else with any other ideas feel free to chime in as well!
 
Where the bolt is pointing is the only place i saw a drop of coolant. Which is a pcv passage.



You can see here how the npt plugs are recessed in. I did a vacuum test and they both held up.
 
Man, I'm about as confused as a cow on AstroTurf. Now in your lower pic the PCV is the small hole that is half cut out closest to us in the pic (not the bypass) right? I've removed a bunch of M90's from GM cars but never really got into where everything is located. With that said then you would have to have a LiM leak near that port, but since it doesn't do it without the IC I don't get it, and can't make heads or tails of it.

I've seen a missing PCV valve cause so much vacuum in the engine that it caused the crank seal to suck in and squeal on the crank journal. Opening the oil cap relieved the vacuum and placing a the PCV back in solved the problem. That was an NA series2 engine that had the UIM (composite) replaced after a backfire and the mechanic didn't put in a PCV. That's the only other thing I would think of that may be relevant.

Jeff
 
Circled is the only pcv passage that is used in my setup. I have a front valve cover breather. Yeah at this point im really at a loss as well.

 


OP. These are the pcv holes..make sure your rear is not blocked by rtv, and make sure you put rtv around the front one even though it's blocked off by the ic, you can still get a Vac leak from it. Doesn't fix your coolant issue but possible vac leak, pcv issue...and you should ditch the breather cap imo and do it correctly so it can be tuned better. If you feel heavy sucking on the oil cap while engine running you have a pcv issue that can cause problems with gaskets as stated...hope you get it figured out.

9dcb7342da1f0c2305c1fb6b186d2576.jpg
 
The smaller hole is one i drilled out to get the rear pvc working with the zzp stage 2 IC. usually they make the hole bigger but i just have it at that size. Here is a pic of what zzp's modified lim's look like.
Both the holes were surrounded with rtv when the ic was installed, its just hard to see in this pic.
 


Beatdowncity said:
The smaller hole is one i drilled out to get the rear pvc working with the zzp stage 2 IC. usually they make the hole bigger but i just have it at that size. Here is a pic of what zzp's modified lim's look like.
Both the holes were surrounded with rtv when the ic was installed, its just hard to see in this pic.
Click to expand...
Ahh got it...might need to open it up a little bit more..
 
I would think with a filter there it would make a pretty heavy sucking noise. It's an easy check. If there was an PCV issue it wouldn't be able to cause a leak in coolant I wouldn't think. I'm sure it's not good, and agree the PCV should work as intended. So with the revised manifolds there is a second passage from the manifold? I'm guessing they were picking up volume? Does anyone know the reason for the difference? I don't know enough about it to say wether modifying it would make the situation worse but we gotta find the root cause I would think with tv feather in there even if there was an PCV issue it wouldn't be able to cause a leak in coolant. I'm sure it's not good, and agree the PCV should work as intended.rather than just start modifying things. I can't think of another thing that could cause it. I looked at the pics carefully and the 2 part IC adapter has A small manifold area inside it. Depending on a lot of things this can actually create a restriction. It's the same effect used in the stock air box. That is a Helmotz resonator. I may be overthinking this.

Jeff
 
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