ATTN: If you have a tune please read

If you are tuned (any tune that raises your boost), please keep an eye on your Intake Manifold for cracks at the seams. I want to bring this to peoples attention on the forums as it has been a hot topic on Facebook the past few days and I haven't seen anyone posting this on here.

Morgan first brought this to our attention here http://www.sonicownersforum.com/forum/1-4l-turbo-sonic-engine-discussion/18755-cracked-intake-manifold-customer-carf.html

There was a long post of people on Facebook who checked (with out suspecting a problem) and vast majority of people who checked also had similar cracks in the seams. I have full bolt ons, only 30k miles on my Sonic, I rarely take it above 4k rpm's, and dont really beat on it. I thought nah this wouldn't happen to me... but it did. My intake manifold is actually splitting in two different areas both at the seams. The one is directly on top and the other bigger one is right next to the throttle body.

I do not have the pictures for this right now but will post in a few hours once I do. The splits are hard to see in the pictures but if you look at the seams and see any separation at all then you have an issue to.

Morgan suggests using JB Kwik Weld and using a clamp to hold the seam together as it drys. Someone else used 3M Scotch-Weld. This seems to fix the specific seam split at that time. Im not sure what to do as a preventative to seal up all the seams on the Intake Manifold, maybe Jb Weld them all? Im not sure maybe you all have a better idea.

TTR was looking into making an aluminum intake manifold but stopped because they said it wouldn't offer significant gains, if any, over stock. Also it looked like not enough people were willing to spend $600 on one. Mods locked this thread after that was declared. This maybe a viable option now if our power levels are blowing the stocker apart. http://www.sonicownersforum.com/forum/turbo-tech-racing/6169-1-4l-aluminum-intake-manifold.html

Well it looks like we found the weak link in our engines.

can you post a link to the Facebook page or group? did anyone post pictures?

What tune do you have? What max boost do you see?

gsfisher13 said:

can you post a link to the Facebook page or group? did anyone post pictures?

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https://www.facebook.com/groups/GammaII/

RMinNJ said:

What tune do you have? What max boost do you see?

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I have Trifecta and see 22 max PSI, the tune doesn't seem to matter as people with BNR and HPTuners have had this happen as well. It seems to be more of the increase in boost/power from mods issue.

Here are the pictures of what mine looks like (each picture is a different crack)





My intake manifold is red but you can see the black in the seam from where it pulled apart.

This is another reason I'm hesitant to get a tune for my new 1.4T. The engine and turbo may be able to withstand the increased boost, but there are numerous other ancillary components that may not, at least not long term.

Then again, are we sure the stock IM is holding up fine for those without a tune? Maybe the seams are simply a weak design, so maybe even folks without a tune should check their seams.

Any codes indicating the issue...ie lean ?

My 2012 manifold is black so it's hard to see the seam coming a part

MORTIS said:

This is another reason I'm hesitant to get a tune for my new 1.4T. The engine and turbo may be able to withstand the increased boost, but there are numerous other ancillary components that may not, at least not long term.

Then again, are we sure the stock IM is holding up fine for those without a tune? Maybe the seams are simply a weak design, so maybe even folks without a tune should check their seams.

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I was wondering this too. Once more people come forward maybe we can make a poll to get more info Ex: with or without porting the intake, tune, full bolt ons, etc.

RMinNJ said:

Any codes indicating the issue...ie lean ?

My 2012 manifold is black so it's hard to see the seam coming a part

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No codes at all which is why this is taking everyone by surpise. I am very in sync with my car and did notice a small power difference but i always thought it was Trifecta. My UG was beginning to fluctuate my long term fuel trims from -+10 ish, which is a little off (you want around +-5). I bought a wideband and it verified all my AFR was good through out the rpm band. So i thought i was just getting use to the power or something. This could be unrelated or coincidence but it does make sense.

I noticed some change over the last few months since my tune. I had been procrastinating intake porting, but I think I might today and see how my intake is holding up.


2012 Chevy Sonic LTZ (hatch)
MPFab CAI, Forge BOV, ZZP Turbo Back, Trifecta Elite Tuned, bypass valve "bypass", MPFab FMIC, Ultra Gauge

Short of an all metal intake maybe this is a chance for one of our kind aftermarket
vendors to maybe offer some metal clips that go along the intake seam and reinforce it/keep it from stressing the glue ?

I suppose its not just max boost pressure either but heat and vibration that stress it..

Wub2Dub said:

I noticed some change over the last few months since my tune. I had been procrastinating intake porting, but I think I might today and see how my intake is holding up.


2012 Chevy Sonic LTZ (hatch)
MPFab CAI, Forge BOV, ZZP Turbo Back, Trifecta Elite Tuned, bypass valve "bypass", MPFab FMIC, Ultra Gauge

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Let us know!

RMinNJ said:

Short of an all metal intake maybe this is a chance for one of our kind aftermarket
vendors to maybe offer some metal clips that go along the intake seam and reinforce it/keep it from stressing the glue ?

I suppose its not just max boost pressure either but heat and vibration that stress it..

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This sounds like a good idea, I wonder if there is enough meat for the clips to bite to it.

(EDIT: looks like there could be, it is decently fat in those areas)

Yes i think it is all the above. It seems like what ever they used to seal the intake is very brittle. I have a feeling that non tuned 1.4's will experience this as well eventually, maybe the 100k mark, unless its granny driven.

Excellent point. Kinda one of those slap in your face moments as it was never expected.
Seems a stronger intake our future it is.

Is this enough to worry about? It doesn't seem cracked, just looks like it's starting to split.

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There's a good chance, with the stock tune capable of 14psi at least at some times, that this will affect most cars eventually. The tune will only make it happen sooner.

The clip idea is great, a little extra mechanical reinforcement will help it from pulling apart.

I see some auto metal body clips look good but they are flat on one side.

http://www.installer.com/photos/scs8.jpg

I was thinking of something like this:

http://www.araymondtinnerman.com/en/resources/images/subfamily/photos/8.jpg


Maybe there is some high temperature glue can seal it with now before it separates?

Those have very little tension but may reduce the seam split if strategically installed. Speculation and hope stinks though...

Sent from my XT1254

RobbyS said:

View attachment 11369View attachment 11370
Is this enough to worry about? It doesn't seem cracked, just looks like it's starting to split.

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Looks like you are ok for the moment but i would definitely keep an eye on it. It probably wont be long... What mods do you have tune, ported intake?

RMinNJ said:

I see some auto metal body clips look good but they are flat on one side.

http://www.installer.com/photos/scs8.jpg

I was thinking of something like this:

http://www.araymondtinnerman.com/en/resources/images/subfamily/photos/8.jpg


Maybe there is some high temperature glue can seal it with now before it separates?

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These with some JB weld might enough to take some of the stress from each other to help hold the pressure. I do like this idea.

Maybe we can see if TTR would be willing to re-look into making the aluminum intake again if enough people are interested.

Yes an aluminum intake would be cool..but the shape is so strange..it would be expensive?

More speculation and hope; is there a gap between the outlet ports such that we could put hose clamps around the entire thing at intervals down the length?

RMinNJ said:

Yes an aluminum intake would be cool..but the shape is so strange..it would be expensive?

More speculation and hope; is there a gap between the outlet ports such that we could put hose clamps around the entire thing at intervals down the length?

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In the thread i linked in first post they were estimating $600, which is high for no gain. To me its worth it for the amount of money i have sunk into this car to have it running right again and peace of mind.

I cant remember what the under side looked like i will have to go through my pictures to see. If i go the clip route I will probably take off the Intake Mani, use JB on the splits heavily, coat the seam all the way around with JB, then place clips on the apex of each bend and probably place clips in 3 inch intervals.

rsSteve said:

Looks like you are ok for the moment but i would definitely keep an eye on it. It probably wont be long... What mods do you have tune, ported intake?

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I only have a cold air intake, exhaust, and a tune. No ported intake.