PSA: Procharger Kits - Intercooler Coupler Blowing Off

[Nemesys]

This is just an informative post to let folks with the Procharger kit that you may want to consider having the tools to remove your front bumper and re-attach couplers on the FMIC connection points.

Twice this past weekend the discharge side of the FMIC (nearest the MAF sensor) I had a coupler blow off under full boost. The first time it happened I attributed it to maybe a loose coupler, not fully tightened down clamp, etc. However before heading to a show this weekend I reinstalled everything and made sure the coupler and clamps were perfect.

On the way home today I hit full boost on the interstate, coupler blew off and all power died on the car and left me in a pretty dangerous situation where I was coasting at full highway speeds in traffic into to a dead stop on the side of the road where I had to re-attach the coupler and get it back home.

From my observations here are some things Id recommend when installing this kit:

1. Use Tclamps instead of the standard on the intercooler connections.

2. Get slightly longer couplers on both sides of the intercooler.

3. Do a grille delete because because stuck on the side of the road trying to take your bumper off completely isnt a good idea.


Being stranded sucks, having to get towed would suck even more. Luckily its just a minor issue but could cause a huge headache for some.

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[sanchezcruz_20]

Can you post a pic of your coupler? Did you cut or trim it during install?

I'm wondering if there was a part change at some point. I felt mine were adequate in length and coverage of the tubes left plenty of overlap/redundancy. I simply can't see how it could possibly "blow" off.

I considered trimming mine for ease of fitment during my install but I decided not too, which resulted in some additional wrestling of the tubes but when it was all said and done, everything was SOLID. I honestly can't see anything blowing off in that area, even WITHOUT clamps haha. At most, there might be some sliding of the couplers and resulting boost leaks.

 

[Nemesys]

Ill post a pic of the coupler in question when I get home, but to answer your question, no the coupler wasnt trimmed.

 

[Poppacapp]

Get a CAN of hairspray. Spray the inside of the coupler before sliding it back on.

 

[S550 KID]

I've had mine on since January/February this year no blow off problems. But I positioned the clamps so that they are accessible through the front grill for future tightening. Also I know a few little tricks to keep them taught. My last car was at 41psi boost lol.

 

[Barrel]

My coupler kept blowing off on the dyno. T-bolts fixed that.

 

[Super Werty]

hairspray

 

[ProChargerTECH]

10,000 blown miles after this weekend of abuse to TX with one of our DEMO's, no coupler has come off. And it was beaten on since day one, including this weekend. (and a couple hundred dyno pulls)

Make sure your tubes are trimmed correctly, so that when they expand with boost, they are not trying to removed it from the intercooler.

I hate T-bolts personally, but then again I have had no issues with worm clams and 28psi of boost, so no reason to change. (I just hate using that 11mm long socket and a million cranks to get something tight, that takes 30 seconds with a standard clamp)

 

[Process]

10,000 blown miles after this weekend of abuse to TX with one of our DEMO's, no coupler has come off. And it was beaten on since day one, including this weekend. (and a couple hundred dyno pulls)

Make sure your tubes are trimmed correctly, so that when they expand with boost, they are not trying to removed it from the intercooler.

I hate T-bolts personally, but then again I have had no issues with worm clams and 28psi of boost, so no reason to change. (I just hate using that 11mm long socket and a million cranks to get something tight, that takes 30 seconds with a standard clamp)

just because your car doesn't do it, does not mean it is not an issue.

If the customer has to check to see if your tubes are trimmed properly, it's your problem, not theirs.

 

[re-rx7]

just because your car doesn't do it, does not mean it is not an issue.

If the customer has to check to see if your tubes are trimmed properly, it's your problem, not theirs.

Ummmm what? Would that be an install oriented problem? I mean doesn't it say int he instruction to trim them for fit?

 

[Process]

Ummmm what? Would that be an install oriented problem? I mean doesn't it say int he instruction to trim them for fit?

I'm reading the usage of the word "tube" to be piping.


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[BathS550]

8500 miles on my setup and I have not had a coupler come loose. Im not sure this is exactly "PSA" Worthy.

You had a coupler come off ... it may have been trimmed by the installer ... it may not have been lined up correctly ... it may not have been tightened adequately.

 

[Process]

I will say though. I've yet to blow a charge pipe off yet either.


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[Phils15GT]

Mine are solid but I did switch to t bolt clamps.

 

[Nemesys]

it may have been trimmed by the installer ... it may not have been lined up correctly ... it may not have been tightened adequately.

I installed the system. It was not trimmed. I re-tightened and re positioned the coupler again after the first time.

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