Installed PRL intercooler and can’t find the leak...

[Deadgame]

I installed my PRL intercooler yesterday and while it should have been a 1 hour job, it turned into 7 hours and I’m still not done...After initial install I took the car for a ride and it will not maintain boost. Vacuum at idle is -11 and when I rev to 3500 rpm, boost fluctuates and returns to -11. I’m looking at LTFTs between 7-10 at idle and
4-5 while cruising. I’ve taken the intercooler on and off no less than 10 times to make sure proper o-ring seal and torqued the bolts to 18 lbs as reccomended by PRL’s website. I’m at a loss here....I guess I’m going to try to pressurize the system to look for a leak. I’ve never done this before, but it looks doable. Questions for those that have:

Is this where I put the plug to pressurize the system? If so, what size rubber coupling do I need to buy to make something similar to the device below?

 

[98-0425]

Put the stock IC back, if it maintains boost then possibly a defective IC.

 

[.grimace]

Put the stock IC back, if it maintains boost then possibly a defective IC.

Yea seems like a good way to go about it, PRL uses the OEM pipes right so it's either loose at either side of the intercooler (which I am sure you've checked 1000x) or it's faulty.

 

[02SilverSiHB]

I think this is about the 5th time I've seen this for people putting on a PRL or Mishi intercooler....each time...it was the install. And each time, they all thought they did the install correctly, but later found they didn't have a proper seal at the O-ring.

I know that's probably frustrating to hear as you've taken it off 10x now...but try again and do it when you're not in a rush. Good luck man.

 

[Deadgame]

Not sure how else you can line the o-rings up...I put them in the grooves and made sure they weren’t popping out. Tightened each bolt back and forth meticulously. Flanges are lined up properly. I do notice that the end tanks where the o-rings go have the groove that is not perfectly oval. They have a jagged pattern that the oem intercooler doesn’t have. I don’t know why this is, but it seems like the o-ring only fits in there one way. This is pretty ridiculous that I’m having this much trouble over something so simple...

 

[02SilverSiHB]

Not sure how else you can line the o-rings up...I put them in the grooves and made sure they weren’t popping out. Tightened each bolt back and forth meticulously. Flanges are lined up properly. I do notice that the end tanks where the o-rings go have the groove that is not perfectly oval. They have a jagged pattern that the oem intercooler doesn’t have. I don’t know why this is, but it seems like the o-ring only fits in there one way. This is pretty ridiculous that I’m having this much trouble over something so simple...

yeah, that sucks man. Have you hit up PRL yet?

 

[Deadgame]

Not yet, worked on it last night and with the holidays and all, I haven’t got a chance yet. I’d like to do the boost leak test tonight and if it’s the intercooler, I’ll call them. I’m at work right now and would like to pick up the parts to make the leak tester on the way home. Can anyone confirm the size of silicone pipe and if this is the correct place to put the tester?

 

[boosted180sx]

PRL does pressure test the intercooler before it gets shipped out so maybe it slipped through or was damaged in transit.

like others have said, i'd first try putting the stock intercooler back on and see if you have any issues.

 

[AREA]

Also when tightening the bolts go back and forth in increments. Don't fully tighten one bolt and then the other or you are already making the mating surface uneven and can get blow by. Just food for thought.

 

[Deadgame]

Also when tightening the bolts go back and forth in increments. Don't fully tighten one bolt and then the other or you are already making the mating surface uneven and can get blow by. Just food for thought.

Yep, tighten the bolts incrementally...

 

[02SilverSiHB]

Not yet, worked on it last night and with the holidays and all, I haven’t got a chance yet. I’d like to do the boost leak test tonight and if it’s the intercooler, I’ll call them. I’m at work right now and would like to pick up the parts to make the leak tester on the way home. Can anyone confirm the size of silicone pipe and if this is the correct place to put the tester?

I don't think that's where you would leak test there for pressure right? That's where the intake is...sucking in air...so no pressure/boost on that end.

I've never used those, but I'd think you'd want to test it after the intercooler? So that pipe that comes up to the engine bay from the intercooler...the one on the right in this pic

But I could be wrong, never used those lol

 

[.grimace]

^^^ I'd agree with him that's the air intake wrong spot. You'd want to get a spot down wind from the turbo where pressure is actually built and sent to the throttle body/ engine.

 

[PRL Motorsports]

Sorry to here of your frustrations. If you are going to boost leak pleas use the turbo inlet pipe as you circled above. That will give you a leak test of the entire system. That is the proper way to do the job.

As for the questions on the oring grooves. The odd shape is there to help hold the oring in place while still leaving adequate room for the Oring to squish.

All inetrcoolers are pressure test before they are packed.

If you are still having issue never hesitate to call or email us direct as that will result in your quickest response

 

[mdub83]

I’m having the same problem as well, I can upload a picture of what the Honda dealer told me... I’m starting to really regret this purchase ...
I have emailed PRL and they said they will sell me new o rings , i feel I should get them free though

 

[02SilverSiHB]

I’m having the same problem as well, I can upload a picture of what the Honda dealer told me... I’m starting to really regret this purchase ...
I have emailed PRL and they said they will sell me new o rings , i feel I should get them free though

I don't man, sounds like you might have just installed it incorrectly...thought they warned about that. hope that fixes your problem.

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