Robert Weber

I checked with Alunox a few times, and the only offering they had was the larger charge cooler offered at a substantial price lift over the previous group buy...actually, nearly double! No mention was made of offering a unit closer in spec to our OEM charge coolers. My concern over the larger unit was the need to modify the engine cover. Oh well....

After months of search, and 2 gracious offers of chargecoolers that proved to have the very same leakage issue as does my OE unit, I've landed one via Geoff at Esprit Engineering In Wilshire! It was removed years ago from a virtually new S4s. It's really hard to imagine that a piece this critical to the operation of our cars is just no longer available....anywhere! I spoke with Jay at JAE and they have one which they paid a tidy sum for it. Our only option is aftermarket. My suspicion is that I'm not alone with this issue. If you are topping-up your chargecooler overflow tank, you likely have a leaking chargecooler. I tried contacting Behr on the availability of cores for refabricated coolers, but received no answer. Bob

Thanks, Chris! I'll stand by. However, I did speak with Pete at PNM today. We spoke at length which is a first with the normally busy Pete. Turns out that in recent weeks, he underwent the removal of a few gall stones, and subsequently the removal of his gall bladder. I caught him at the office sequestered at his desk chair under strict orders to not do any work....thus, our speaking at length. He hopes/intends to be back in the flow within a week, at which time he'll address the chargecooler refit. Fingers are crossed. So, Chris, in the event that Pete doesn't come through, I'm atop your list. Bob

Heard from Alistair today, and as it turns-out, his chargecooler had the same issue. Alistair was kind enough to have the unit pressure tested, and there was leakage into the intake side of the chargecooler. It makes me wonder how many other chargecooled cars have the same issue and owners are unaware of it? Monitor your chargecooler coolant reservoir carefully and if you are refilling it periodically, you likely have a leaker. I'm awaiting word from Pete at PNM as they are able to rebuild/re-core the OEM chargecooler. There's a bit of a delay on new cores, but if this does not work-out, I will abandon my intent to remain as OE and go to an Alunox chargecooler (if they are still available). The truly bad news is that the Esprit has sat for the past 2 months in the garage.... Bob

Thanks, Alastair.

That is exactly the issue, Filip. Owners with used chargecoolers sought 480 pounds for their unit and there was no telling if they had the same issue. I have just sent my chargecooler to Pete at PNM Engineering for a rebuild. Here's his note to me: Hi Bob, This is not an uncommon problem, it’s due to corrosion caused when there is insufficient water in the cooler and the water / air interaction corrodes the insides. This is mainly when cars are left standing for long periods when the levels are not topped up. We can replace the charge cooler element if you send us your old unit. Thanks, Pete PNM

Thanks, Barry.

Improbably, the intercooler on my '94 S4 is leaking. I'm told by many who know better that this just never happens, but I've discovered coolant inside the plenum of my car (along with drippings on the side of the block). The coolant manifests itself under higher rpm's and boost, so my suspicion was that as the pump increases speed/flow/pressure....leakage occurs. Sure enough, upon removing the chargecooler, filling the 'intake' side with water and applying air pressure to the 'coolant' side of the chargecooler, bubbles appeared. There's no repairing these chargecoolers from what I understand. I am in need of an OEM chargecooler in the event someone has one or knows where to source one. Seeking to keep the car original, I'm really not interested in an aftermarket unit unless I have no choice. Goodness, there must be a Lotus salvage yard in the UK with a few of these laying on a shelf? Thanks in advance for your help. Best, Bob

Improbably, the intercooler on my '94 S4 is leaking. I'm told by many who know better that this just never happens, but I've discovered coolant inside the plenum of my car (along with drippings on the side of the block). The coolant manifests itself under higher rpm's and boost, so my suspicion was that as the pump increases speed/flow/pressure....leakage occurs. Sure enough, upon removing the chargecooler, filling the 'intake' side with water and applying air pressure to the 'coolant' side of the chargecooler, bubbles appeared. There's no repairing these chargecoolers from what I understand. I am in need of an OEM chargecooler in the event someone has one or knows where to source one. Seeking to keep the car original, I'm really not interested in an aftermarket unit unless I have no choice. Thanks in advance for your help. Best, Bob

I've learned that SJS sells a reproduction piece and the hardware.

I do not see the listing for the deflector. Has it been sold? If so, where does one go to find another as my S4 car is missing the deflector. Thanks! Bob

$144 US Dollars from JAE. Also replaced the flat washer while I was in there. All in all, though I'm not happy that this happened and added to all the work already done, I'm thrilled that I caught this early-on and avoided a catastrophic failure, not to mention the learning that servicing the timing and accessory belts can be done with the engine in place. Not so sure that I'd try a water pump replacement in-situ, but lifting the engine/transaxle (with the correct equipment) is also a very doable task.

The new parts arrived from JAE and I set out to replace the sprocket from under the car. Travis' help was fantastic and he helped talk me off the ledge to the point that (now with the major service performed on the car) future cam belt changes can, indeed, be down in-situ. I'm nearly finished and it's gone surprisingly well. Here's a couple of photos of the crankshaft sprocket, and you will note not only the fractured tooth but a crack clear-through the sprocket. This was a time bomb in the making. Others in the States seem to be seeing this occurrence on S4 cars, so changing the sprocket would seem to be a compulsory action when replacing the timing belt, or (at least) a very careful examination or crack testing. Thank you to all who offered advice and counsel! Cheers, Bob

While referencing PNM, I also upgraded my braking system with their 4-pot caliper and slotted rotor kit. Spax shocks were installed at the same time.

Thank you, Jeremy! A few more shots.... All of which is why I hesitated when it came to the Alunox....