New '03 owner with a 'broken' car, advice needed (long post, sorry)

UFO

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I am now the 'proud' owner of a heavily built '03 Cobra, the car is set up for HPDE with Full Tilt Boogie everything along with Maximum Motorsports bits and Brembo BBK. Engine also has a lot of work done to it and with the VMP blower she makes 600/600 to the wheels on a conservative tune. The car had been sat for a few years before I picked her up, so I switched out the tires, changed the oil, ran a few tanks of fuel through her, flushed the brakes, and headed out to MSR Houston for my first track day in my new car. 2 laps in to my first session the car's hitting limp mode and there's spots on my windshield, I pit in and coolant is leaking out of the ring seal of my Lethal Performance intercooler reservoir tank. After some troubleshooting the intercooler reservoir tank pump had failed, the alternator's also giving up the ghost.

Thanks to friends the pump and alternator are replaced at the end of the day and I'm ready to roll first session Sunday morning. 3 laps in and I'm flying, the car is running strong and I have a shit eating grin on my face until I hit turn 3 and I can't see where I'm going as my windshield is covered in coolant. No limp mode this time, the seal on the cap of the tank blew out, cap doesn't even seal properly any more and the ring is all corroded. Kind of pissed that I got to run 5 laps over the weekend and it cost me around $2K but whatever, ordered a new cap and ring kit for the reservoir and installed it today. Headed out to Mexico and did some hard pulls, the tank is leaking from the cap again. I have reached out to Lethal Performance and they were about as useful as their reservoir tank is, they suggested it might need bleeding with no suggestion on how to do that.

If I pull the cap off the reservoir tank the pump doesn't run on startup, it only runs once the engine warms up, is that normal? When it does run you can it's very obvious it's running. It's almost like there's just too much pressure in the tank, there's a screw on the cap, should I loosen that to release pressure?

Here's some pictures for context:
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RAUMem1.jpg

New cap and ring/mounting hardware installed.
1KampxS.jpg
 

HudsonFalcon

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That sucks man.

Honestly i would ditch that tank in favor of a trunk mounted setup if you're tracking it. Maybe look into a 160° thermostat.

Trunk Mounted Intercooler Reservoir | J2 Fabrication

Also, the pump doesn't come on until the coolant gets up to temp but you can use a jumper to see if it's working properly. You can do a search and find the thread.

Welcome to the forums.
 

SVTdreamin04

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Make sure the cap is venting properly and the tank isn't overfilled. You may also have an issue with the tubes that fit into the intercooler via o rings. This has caused many issues before. Also, make sure there are no restrictions in the intercooler coolant system. When I bought my car, I found that the seal from an antifreeze jug was lodged in the intercooler pump it line causing my pump to loose flow at times, which caused the coolant temps to climb.


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olympic

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There shouldn't be any pressure in that tank. There's only 2 places the pressure can come from: overheating the IC fluid or from boost pressure finding it's way into the IC system. This could come leaking O-rings in the intercooler pass-through or a crack in the intercooler itself.
 

94 Cobra R

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If you're intercooler tank is overfilled, which is easy to do when there's not markings on the tank that say "max" you can have that problem. But I agree with HudsonFalcon, i'd do a trunk mount tank, otherwise, you're going to start getting some pretty high IAT2 numbers. Do you have any gauges to monitor that?

Hate to say it, but this is why I'm always leery about buying a car that's been heavily modified, you never know exactly what's been done, even maintenance-wise. You're brave to do a track event without doing some hardcore testing beforehand. Hopefully it's not a big deal. Keep us posted on your progress.
 

01yellercobra

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If the tank itself is corroded no amount of new seals is going to fix it. Get a new tank at least. As mentioned the intercooler pump doesn't come on until a certain temp. A tuner can set it up to come on as soon as the car starts. I think that's how most set it up.

It looks like that breather is a little rusty. I'd guess it's clogged as well.
 

UFO

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That sucks man.

Honestly i would ditch that tank in favor of a trunk mounted setup if you're tracking it. Maybe look into a 160° thermostat.

Trunk Mounted Intercooler Reservoir | J2 Fabrication

Also, the pump doesn't come on until the coolant gets up to temp but you can use a jumper to see if it's working properly. You can do a search and find the thread.

Welcome to the forums.

That's a possibility but before this car was parked for a few years it ran fine *as is*, I'd rather not try to reinvent the wheel if I don't have to. I already need to replace the return type fuel system as the hoses are seeping, gas smells freak me out ;), and do some other stuff so trying to keep cost down.

What you mean by costing you about 2k ?

Track fees, hotel, gas/food, new alternator, new auxiliary water pump, and 4 X Nitto NT01s. Granted, it needed new tires, I was just listing how much the weekend cost me, it's kind of irrelevant and I was just bitching :(.

Are you sure the coolant isn’t getting over-pressurized due to another issue?

No, and I don't know how to check.

Make sure the cap is venting properly and the tank isn't overfilled. You may also have an issue with the tubes that fit into the intercooler via o rings. This has caused many issues before. Also, make sure there are no restrictions in the intercooler coolant system. When I bought my car, I found that the seal from an antifreeze jug was lodged in the intercooler pump it line causing my pump to loose flow at times, which caused the coolant temps to climb.


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How do i know if the tank is overfilled, it's a solid tank with no fill marks? Also, is there a way to test the cap is venting properly. There's no instructions :(.

There shouldn't be any pressure in that tank. There's only 2 places the pressure can come from: overheating the IC fluid or from boost pressure finding it's way into the IC system. This could come leaking O-rings in the intercooler pass-through or a crack in the intercooler itself.

Car has been sat for 2 years or so so leaking O rings would seem like the likely culprit. Hopefully.

If you're intercooler tank is overfilled, which is easy to do when there's not markings on the tank that say "max" you can have that problem. But I agree with HudsonFalcon, i'd do a trunk mount tank, otherwise, you're going to start getting some pretty high IAT2 numbers. Do you have any gauges to monitor that?

Hate to say it, but this is why I'm always leery about buying a car that's been heavily modified, you never know exactly what's been done, even maintenance-wise. You're brave to do a track event without doing some hardcore testing beforehand. Hopefully it's not a big deal. Keep us posted on your progress.

Car belonged to a friend of a friend, I know its maintenance schedule, know who did the work and know who tuned the car and the suspension so whilst I agree buying someone else's project is never a good thing I thought I would luck out here. Looks like I might have been wrong ;).

No gauges at all, something I hope to remedy soon. And, again, I don't know how full is too full?

If the tank itself is corroded no amount of new seals is going to fix it. Get a new tank at least. As mentioned the intercooler pump doesn't come on until a certain temp. A tuner can set it up to come on as soon as the car starts. I think that's how most set it up.

It looks like that breather is a little rusty. I'd guess it's clogged as well.

When I changed the cap I drained most of the coolant out and used a flashlight to look inside, it's remarkably clean and corrosion free from what I can see.

Thanks everyone for the comments, gives me something to go on.[/QUOTE][/QUOTE]
 

01yellercobra

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When it comes to filling the reservoir I keep it under the inlet. But I have True Forged tanks. I want to say about an inch below the inlet.
 

94 Cobra R

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When it comes to filling the reservoir I keep it under the inlet. But I have True Forged tanks. I want to say about an inch below the inlet.

Correct, keep it under the inlet and @UFO will be fine.

I would highly recommend getting a dual AeroForce Interceptor setup (Aeroforce Technology Inc | Products - Interceptor) and getting a wideband and a boost gauge.

Replace the cap of the intercooler reservoir and then you won't have to worry about it not sealing or venting.

Fuel lines (especially the more economical ones) can smell, probably not leaking. PTFE is the hose to go with but I wouldn't make that my priority. Interesting it has a return setup on a 600rwhp motor. Good for planning in the future, I suppose.

I would really recommend that tank mount intercooler, otherwise you're going to experience problems tracking that car and timing will get pulled as that IAT2 climbs.
 

SVTdreamin04

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The cap has holes in it that you can see where you turn it upside down. The bolt with the odd looking washer that is on the top of the cap is where the cap vents to. You don't need to buy a new cap as this can be tested. I removed the bolt and ran compressed air to it to check for venting.


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SVTdreamin04

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Overfilling the tank will not allow the tank to vent properly, which in turn will not allow for flow out of the tank and into the intercooler pump. If the water level is to the cap, this can happen. It's just like a gas tank, it has to be vented to atmosphere somehow. FYI, these intercooler pumps really don't pull a vacuum, so the inlet must not have any type of restrictions.


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UFO

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When it comes to filling the reservoir I keep it under the inlet. But I have True Forged tanks. I want to say about an inch below the inlet.

OK, thanks, now I need to Google which way the system flows and which is the inlet ;). I'd say it's definitely overfilled, I'm about 1.5" below the top of the tank. It's only my 2nd ever Mustang (I'm coming from a Scion FR-S) and I've only had her 2 months or so, so it's going to be a learning process.
 

UFO

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Correct, keep it under the inlet and @UFO will be fine.

I would highly recommend getting a dual AeroForce Interceptor setup (Aeroforce Technology Inc | Products - Interceptor) and getting a wideband and a boost gauge.

Replace the cap of the intercooler reservoir and then you won't have to worry about it not sealing or venting.

Fuel lines (especially the more economical ones) can smell, probably not leaking. PTFE is the hose to go with but I wouldn't make that my priority. Interesting it has a return setup on a 600rwhp motor. Good for planning in the future, I suppose.

I would really recommend that tank mount intercooler, otherwise you're going to experience problems tracking that car and timing will get pulled as that IAT2 climbs.

I did replace the cap already, it's the black one in the pictures. The car used to make 1K so that's the reason for the fuel system. But, yes, going to keep it return type and replace with PTFE hoses at the earliest. Thanks for the heads up on the gauge, I will check it out.
 
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UFO

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The cap has holes in it that you can see where you turn it upside down. The bolt with the odd looking washer that is on the top of the cap is where the cap vents to. You don't need to buy a new cap as this can be tested. I removed the bolt and ran compressed air to it to check for venting.


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The ring for the old cap had some corrosion on it and wasn't sealing properly so I replaced the ring, seal, bolts, and cap with replacements from Lethal Performance (actually Moroso parts). I do believe the bottom of the cap is hitting the coolant so it's pretty certain its overfilled. Thanks for the heads up.
 

01yellercobra

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OK, thanks, now I need to Google which way the system flows and which is the inlet ;). I'd say it's definitely overfilled, I'm about 1.5" below the top of the tank. It's only my 2nd ever Mustang (I'm coming from a Scion FR-S) and I've only had her 2 months or so, so it's going to be a learning process.

The top one facing the engine is the inlet/return.
 

UFO

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The top one facing the engine is the inlet/return.

When I actually looked at the tank again I realized how dumb my question was ;). Thanks for being gentle with me =).

Tank wasn't overfilled, waiting on O rings to be delivered. Fingers crossed!
 

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