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BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Powertrain and Drivetrain Discussions > N54 Turbo Engine / Drivetrain / Exhaust Modifications - 335i > AMS Intercooler Boost Leak



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      07-23-2012, 02:44 PM   #1
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AMS Intercooler Boost Leak

I had a boost leak issue and it turned out the be the passenger side coupler on the intercooler. I have "fixed" it three times now and it keeps coming off slightly after I build boost once. The coupler provided by AMS is not long enough to completely cover the intercooler and the turbo piping hence comprises needing to be made. I have tried to find a happy median but either way the coupler leaks on one side or the other.

So my question is what kind of coupling should I buy to replace this. I believe 2" to 3" coupler? Should I get one with a bend or should a straight one work when it's clamped down. There is a slight bend in the one on there now, but not very significant.
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      07-23-2012, 02:47 PM   #2
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This happened to me. Eventually I just had a shop weld on longer ends so the couplers would never pop off
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      07-23-2012, 02:59 PM   #3
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Quote:
Originally Posted by jpsimon View Post
This happened to me. Eventually I just had a shop weld on longer ends so the couplers would never pop off
Haha I'm not there yet, but I am starting to understand that kind of mentality. At this point I want to see if there is a cheaper DIY solution.
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      07-23-2012, 03:09 PM   #4
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I can't comment on the angle, but it sounds like you just need some straight silicone tubing, custom cut and some T bolt clamps.
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      07-23-2012, 03:30 PM   #5
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Yea that is what I will most likely do once I get a bead on the diameters I will need.
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      07-23-2012, 08:54 PM   #6
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Come on someone has to know the size coupler I need.
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      07-23-2012, 09:23 PM   #7
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Take yours and match it up at the place you buy it from or measure it or e mail the ic company or.......

When you get the longer one use wd40 to clean and wipe all the oil off.
After that use wd40 to lube the new hose, it will slip on with ease and don't worry wd40 drys
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      07-23-2012, 09:27 PM   #8
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Quote:
Originally Posted by Randomaccess335 View Post
Take yours and match it up at the place you buy it from or measure it or e mail the ic company or.......
...wing it. http://www.ebay.com/itm/Black-Silico...ht_2895wt_1114

5" should be long enough.
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      07-23-2012, 09:40 PM   #9
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Ams makes 2 Intercoolers one for 07/08 and one for 09+
And the hose ur looking at is a reducer in the Modbargins add it's looks to be 3" both ends
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      07-24-2012, 01:30 PM   #10
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Quote:
Originally Posted by Randomaccess335 View Post
Ams makes 2 Intercoolers one for 07/08 and one for 09+
And the hose ur looking at is a reducer in the Modbargins add it's looks to be 3" both ends
The stock turbo pipe is definitely not 3", hopefully 2" is correct.

I believe it is referencing that the intercooler is 3" at both ends, not the reducer.
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Last edited by tcw; 07-24-2012 at 01:36 PM..
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      07-24-2012, 08:07 PM   #11
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Yeah, its a puzzle... Took me a good hour continually rotating, arranging the fit and finally solved it. BUT I understand there was a revision early on. Not sure which one I had, but if it was the revised one, I declare rev1 impossible to "confidently" secure.

JP's solution is probably best for peace of mind and ease.
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      07-24-2012, 08:40 PM   #12
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You need a 2.5" coupler for the OEM side
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      07-24-2012, 08:50 PM   #13
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Quote:
Originally Posted by Tiago@VRSF View Post
You need a 2.5" coupler for the OEM side
Dammit.. lol
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      07-24-2012, 09:59 PM   #14
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I saw someone said stock is 2.5...... My ets ic must be 2.5 same as stock cause my hose is se size both ends.

Ams must bigger inlet if he needs a reducer...... The pics I saw on Modbargins of it appeared to be same size both ends of the hose for ams, sorry if misled you
R
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      07-25-2012, 03:09 PM   #15
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Well the intercooler pipe is definitely larger. For reference:

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      07-26-2012, 09:34 PM   #16
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Shoot! My car's in the shop literally right now having it installed! Is it true that this issue was resolved with later models? Or does it affect recent AMS intercoolers too?
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      07-26-2012, 09:38 PM   #17
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Quote:
Originally Posted by Glowin View Post
Shoot! My car's in the shop literally right now having it installed! Is it true that this issue was resolved with later models? Or does it affect recent AMS intercoolers too?
as joshboody mentioned...there was an early revision in the design that made the pipe extend out a bit longer...so that it extended into the coupling for a more secure fit. i actually have one of the first intercoolers from AMS with the short side.....and have never had an issue with the coupler blowing off...not once.
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      07-27-2012, 01:50 PM   #18
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Well I ordered this so we will see....


http://www.ebay.com/itm/250881407778...ht_4806wt_1348
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      07-27-2012, 08:40 PM   #19
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Quote:
Originally Posted by import36 View Post
as joshboody mentioned...there was an early revision in the design that made the pipe extend out a bit longer...so that it extended into the coupling for a more secure fit. i actually have one of the first intercoolers from AMS with the short side.....and have never had an issue with the coupler blowing off...not once.
Well, I had fired off an email to AMS, and this is what they said to me interestingly enough:

"The silicone has never be altered or changed. I think the issue is that people are trying to use the factory mounting hole for the stock IC piping on that side and if you do, you will not be able to put the silicone coupler all the way on the FMIC hard pipe. You do not want to re-mount the intercooler piping in the factory mounting brackets."

I couldn't speak to my tech who installed the intercooler today to see what he did. Does this sound familiar to anyone here?
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      07-27-2012, 09:14 PM   #20
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Quote:
Originally Posted by Glowin View Post
Well, I had fired off an email to AMS, and this is what they said to me interestingly enough:

"The silicone has never be altered or changed. I think the issue is that people are trying to use the factory mounting hole for the stock IC piping on that side and if you do, you will not be able to put the silicone coupler all the way on the FMIC hard pipe. You do not want to re-mount the intercooler piping in the factory mounting brackets."

I couldn't speak to my tech who installed the intercooler today to see what he did. Does this sound familiar to anyone here?
they didn't alter the silicone.....they lengthened the hard pipe on the passenger side of the intercooler.....so that it extended further into the silicone coupler so it wouldn't blow off.
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      07-28-2012, 07:59 PM   #21
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Fixed!
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      07-28-2012, 10:58 PM   #22
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The host could have been an inch longer when I did mine but if you don't slide it all the way on the factory piping and esure that there is even spacing on both the pipe and IC it should be fine. I can also tighten the pipe side first and force more onto the IC and get another 1/8 inch.
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