Challenge when installing CSF intercooler

[Christopher72]

On installing the CSF intercooler on my N54, I ran into an issue with the outlet connection to the factory charge pipe. I was having a heck of a time getting the FMIC and the pipe to join correctly, and one side of the retaining metal snapped off (not the external clip).

Does anyone have an idea of how to proceed? Is there a silicone coupler that will resolve this, or do I just need to get a new charge pipe?

[B21]

Is that a stock size / stepped or big stepped FMIC?

The Wagner Evo 1 I used which was a 5” stepped cooler and fitted ok..

The Evo 3 comes with its own hoses…having said that a friend in Italy is struggling with his new VSRF charge pipe and turbo outlets connection even with those hoses..

[Christopher72]

It fits in the space okay with a bit of adjusting of the surrounding plastic. It's about 5.5" deep versus the 4-1/4" of the stock. it's a little above the front of the condenser, maybe another 1"+. I picked it up because it had factory connectors... needless to say, I spent more time on this "plug and play" than I would have if I had chosen a Wagner or VRSF. I just unscrewed the front cross piece and left it out since it would block the lower inch of the intercooler.

The hot end connected with a little bit of negotiation... the cold end was horrendous -- and forcing it just made me regret it. Is there an easy replacement to an aftermarket cold-end charge pipe? I'm not looking for BOV port or injection additions. Just an easy fix to get this sealed up.

[B21]

It fits in the space okay with a bit of adjusting of the surrounding plastic. It's about 5.5" deep versus the 4-1/4" of the stock. it's a little above the front of the condenser, maybe another 1"+. I picked it up because it had factory connectors... needless to say, I spent more time on this "plug and play" than I would have if I had chosen a Wagner or VRSF. I just unscrewed the front cross piece and left it out since it would block the lower inch of the intercooler.

The hot end connected with a little bit of negotiation... the cold end was horrendous -- and forcing it just made me regret it. Is there an easy replacement to an aftermarket cold-end charge pipe? I'm not looking for BOV port or injection additions. Just an easy fix to get this sealed up.

Sorry to hear that…I went from an EVO1 with factory connections that I used both on my N20 and N54 then to Evo 3 but that was uprated plumbing…

[Nick9one1]

I have a stepped intercooler and had the same problem installing mine - it needs a lot of force to allow it to seat correctly.
I found that removing the lower part of the charge pipe and connecting out of the car was the easiest option.
There is just enough room to install with the lower part attached to the intercooler.

Screenshot 2023-09-26 135111.jpg (48.98 KiB) Viewed 631 times

remove the T clamp (10 mm socket) marked by the red arrow.

[Christopher72]

I have a stepped intercooler and had the same problem installing mine - it needs a lot of force to allow it to seat correctly.
I found that removing the lower part of the charge pipe and connecting out of the car was the easiest option.
There is just enough room to install with the lower part attached to the intercooler.

Screenshot 2023-09-26 135111.jpg

remove the T clamp (10 mm socket) marked by the red arrow.

Nik, that's excellent advice. Unfortunately, the part between the red arrow and the intercooler is now my problem. The metal retention part of the join is broken, so I can't lock it in place with a clip. So, I'm looking for another OEM connection cold end part that would reach the red arrow t-clamp. Any ideas there? Are there aftermarket options in that connection?

[Christopher72]

remove the T clamp (10 mm socket) marked by the red arrow.

Looks like I have a factory band there... What size T-Clamp and Which brand do you or B21 recommend?

[B21]

remove the T clamp (10 mm socket) marked by the red arrow.

Looks like I have a factory band there... What size T-Clamp and Which brand do you or B21 recommend?

These type are v good


https://www.waltonmotorsport.com/produc ... 20Shopping

Or not quite as good but better than normal stuff..


https://www.txautosport.co.uk/products/ ... -available

[Nick9one1]

I understand what you mean now - the factory lower charge pipe has the tab broken off.

Screenshot 2023-09-27 103350.jpg (184.56 KiB) Viewed 565 times

You can buy the stepped intercooler with a factory connection, or with a connection for a silicone hose. It's not possible to attach a silicone hose directly to the factory style connector.

I think you have two options;
Buy a replacement stock lower charge pipe.
Or see if you can find an adapter - This is for a 335d so unlikely to fit. But someone may produce one for the N54

https://mtcmotorsport.co.uk/products/mt ... 91-e92-e93

[Nick9one1]

edit - I think this is what you need

https://www.darksidedevelopments.co.uk/ ... apter.html

[B21]

edit - I think this is what you need

https://www.darksidedevelopments.co.uk/ ... apter.html

That’s a good to know

Wish I knew about that before I spent a lot more on an Evo 3 to get around that problem….

[Christopher72]

I understand what you mean now - the factory lower charge pipe has the tab broken off.

I did find a suspect used upper and lower charge pipe on ebay and purchased it. Hopefully that pans out -- but I'll take a look at that adapter, I really appreciate you finding that one.

[Nick9one1]

edit - I think this is what you need

https://www.darksidedevelopments.co.uk/ ... apter.html

That’s a good to know

Wish I knew about that before I spent a lot more on an Evo 3 to get around that problem….

To be fair, the EVO3 is a better solution as it has a larger and smoother flow. So dont feel too annoyed about it

[B21]

edit - I think this is what you need

https://www.darksidedevelopments.co.uk/ ... apter.html

That’s a good to know

Wish I knew about that before I spent a lot more on an Evo 3 to get around that problem….

To be fair, the EVO3 is a better solution as it has a larger and smoother flow. So dont feel too annoyed about it

I feel better now..one hell of a chunk of alloy hanging out there in the breeze..but the IATs are steady n cool..

[Christopher72]

Some pictures:









Even with the replacement cold side charge pipe and all the leeway of freedom of movement. I was able to get it fully clipped in and flush, but after reconnecting back to the throttle body it flexes at the join. CSF advertises this as a clean factory fit for the Z4.. the angle is off, or it wouldn't stress like this. I'm tired of messing with it, and I can't give it any relief so this is going to have to do and see how it goes. It is pretty darn secure though.