Wagner Intercooler broke....

kleach18 · 04-23-2013, 03:39 AM

A German friend of mine who has FBO's on his 09 135i had some boost problems recently... Took his front bumber off to check for boost leaks and found this!

He contacted Wagner (sent pictures)and they are sending him a replacement under warranty... He is going to upgrade to the EVO2 and only pay the difference.

Strange how this happened but glad to hear Wagner honoring their 5 year warranty!

SfValley335i · 04-23-2013, 07:56 AM

Wow thats a big failure... even the chinese intercoolers havent failed like this....

Ammonia · 04-23-2013, 08:01 AM

Quote:

Originally Posted by kleach18

He contacted Wagner (sent pictures)and they are sending him a replacement under warranty... He is going to upgrade to the EVO2 and only pay the difference.

Strange how this happened but glad to hear Wagner honoring their 5 year warranty!

Unfortunate situation, but thats the kind of customer service that I love to hear about

TheRuss · 04-23-2013, 08:24 AM

Yikes! I was trying to decide between this and the Forge unit, but I think that's made my decision up for me. Sure, they'll replace it, but what sort've damage could that do? I assume that dirty, unfiltered air would've been going in through that hole straight into the engine?

rjwojcik · 04-23-2013, 08:28 AM

Any idea what could have caused it? Do you think it's a manufacturing fault or did he hit something? Ta

foghat · 04-23-2013, 08:29 AM

Doesn't look like it due to lack of scratches, but did he maybe somehow bottom it out on something?

Lifestyler · 04-23-2013, 08:52 AM

its my car !

and NO,i dont hit something! i dont know how is this happend, the fmic is broken ot both ! sides...

i called wagner tuning and tell my problem, they VERY friendly and say the send me a new one (i chose the evo II like kris sayed) ! i called yesterday,and today they send it to me,so i hope the new FMIC arrives tomorrow !

wagner tuning is very customer friendly, big thx for this!

TheRuss · 04-23-2013, 09:05 AM

Thanks for sharing! So you think this was probably caused by boost pressure? Or metal fatigue from the heating/cooling? Looks like it's broken on the weld.

Lifestyler · 04-23-2013, 09:08 AM

material default i think,its broken exactly byside the welds...

i share some pic when my evo II arrived and i do the install

TheRuss · 04-23-2013, 09:16 AM

What's the difference with the Evo2? Just hoses instead of stock couplers?

nwmark · 04-23-2013, 05:28 PM

Quote:

Originally Posted by TheRuss

What's the difference with the Evo2? Just hoses instead of stock couplers?

From the pictures on the website, it looks like its just hoses and clips extra.

Johnny_M · 04-23-2013, 08:49 PM

That is unfortunate Lifestyler. I'm glad to hear that you received great customer service from Wagner at least. I have a Wagner FMIC as well and it has been running strong and I've had no issues. I can't wait until Helix sees this though...

Suds · 04-23-2013, 11:18 PM

Quote:

Originally Posted by Lifestyler

material default i think,its broken exactly byside the welds...

i share some pic when my evo II arrived and i do the install

What tune were you running, if you don't mind?

Also if you can measure the thickness of the failed bottom plate?

I was going to calculate the pressure load on the bottom plate to see what kind of shear stress that welded area was under.

I also have the Wagner and am curious.

cooler2442 · 04-23-2013, 11:39 PM

Great for Wagner to step up but this shouldn't have happened in the beginning. Seems like quality control just isn't there.

RimasRS · 04-24-2013, 06:30 AM

........ 700 eur in europe for this???? ....

ace11 · 04-24-2013, 07:58 AM

Quote:

Originally Posted by Netw3rk

That is unfortunate Lifestyler. I'm glad to hear that you received great customer service from Wagner at least. I have a Wagner FMIC as well and it has been running strong and I've had no issues.

+1

Lifestyler · 04-24-2013, 08:25 AM

the evo II is way bigger then the evo I !
the new FMIC is arrived today... i install it now !

post later some pics, so long guys

TheRuss · 04-24-2013, 08:43 AM

Does it require any more cutting than the Evo1? They both look the same in the pics online!

Cozy · 04-24-2013, 09:15 AM

This could be a one off, I hope so but their V1 downpipes also suffered some kind of cracking issue at the bracket if I remember rightly. Still, problems happen and it's more about the service you receive that counts in that case. I nearly bought this cooler but instead opted for an ETS which I hope will give me no issue.

TheRuss · 04-24-2013, 10:24 AM

Quote:

Originally Posted by Cozy

This could be a one off, I hope so but their V1 downpipes also suffered some kind of cracking issue at the bracket if I remember rightly. Still, problems happen and it's more about the service you receive that counts in that case. I nearly bought this cooler but instead opted for an ETS which I hope will give me no issue.

Hi mate - why did you choose the ETS and where did you get it from? Shipped across from the US, or is there a UK supplier?

first350 · 04-24-2013, 11:06 AM

would be interested to hear about their welding processes...the IC installation doesn't appear to put a lot of forces on the unit, so I wonder if they didn't pre/post-heat during the welding process; there's a lot of thermal stresses that can be introduced during welding. Only stress it needs to handle are pressure cycles from boost.

TunedM2C · 04-24-2013, 11:45 AM

That's crazy. Maybe you received an early protype? Good thing they're replacing it.

04-23-2013, 03:39 AM	#1
kleach18 Essayons 44 Rep 424 Posts Drives: 2013 135i Join Date: Aug 2012 Location: Dallas, Tx iTrader: (1)	Wagner Intercooler broke.... A German friend of mine who has FBO's on his 09 135i had some boost problems recently... Took his front bumber off to check for boost leaks and found this! He contacted Wagner (sent pictures)and they are sending him a replacement under warranty... He is going to upgrade to the EVO2 and only pay the difference. Strange how this happened but glad to hear Wagner honoring their 5 year warranty! Attached Images __________________ / 135i - M-Sport / 6-Speed / BMW Performance Exhaust / BMS Intake / JB4 Stage 2 ISO + Flex Fuel Wires / BMS 3.5in Down Pipe / CP-E Charge Pipe / Walbro 255 in-line fuel pump / BMS H8 AE / BMS SSK / APEX EC-7's with Nitto NT05's / COBB Tuning Sport Springs / Koni Yellows / Wagner Evo 1 / Blacklines / iCarbon Rear Diffuser / BMW Performance shift knob/boot / BMW Performance Steering Wheel /
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04-23-2013, 07:56 AM	#2
SfValley335i Colonel 164 Rep 2,409 Posts Drives: Current:135i Sold:335i sedan Join Date: Mar 2007 Location: City of Angels iTrader: (8)	Wow thats a big failure... even the chinese intercoolers havent failed like this....
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04-23-2013, 08:24 AM	#4
TheRuss Lieutenant 28 Rep 408 Posts Drives: BMW 135i Join Date: Sep 2012 Location: South West, UK iTrader: (0)	Yikes! I was trying to decide between this and the Forge unit, but I think that's made my decision up for me. Sure, they'll replace it, but what sort've damage could that do? I assume that dirty, unfiltered air would've been going in through that hole straight into the engine?
	Appreciate 0 Quote

04-23-2013, 08:28 AM	#5
rjwojcik Captain 282 Rep 707 Posts Drives: 2016 VW Golf GTD Join Date: Mar 2011 Location: Essex, UK iTrader: (0)	Any idea what could have caused it? Do you think it's a manufacturing fault or did he hit something? Ta __________________ Current: 2016 Golf GTD with a "lot" of toys Gone: 2016 M3 CP - Mineral Grey / Black Gone: 2009 135i - Le Mans Blue / Black
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04-23-2013, 08:29 AM	#6
foghat Captain 59 Rep 913 Posts Drives: 2008 135i Join Date: Jun 2009 Location: Great White North iTrader: (1)	Doesn't look like it due to lack of scratches, but did he maybe somehow bottom it out on something?
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04-23-2013, 08:52 AM	#7
Lifestyler Banned 115 Rep 320 Posts Drives: F80 m3 competition Join Date: Nov 2010 Location: Germany iTrader: (0)	its my car ! and NO,i dont hit something! i dont know how is this happend, the fmic is broken ot both ! sides... i called wagner tuning and tell my problem, they VERY friendly and say the send me a new one (i chose the evo II like kris sayed) ! i called yesterday,and today they send it to me,so i hope the new FMIC arrives tomorrow ! wagner tuning is very customer friendly, big thx for this!
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04-23-2013, 09:05 AM	#8
TheRuss Lieutenant 28 Rep 408 Posts Drives: BMW 135i Join Date: Sep 2012 Location: South West, UK iTrader: (0)	Thanks for sharing! So you think this was probably caused by boost pressure? Or metal fatigue from the heating/cooling? Looks like it's broken on the weld.
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04-23-2013, 09:08 AM	#9
Lifestyler Banned 115 Rep 320 Posts Drives: F80 m3 competition Join Date: Nov 2010 Location: Germany iTrader: (0)	material default i think,its broken exactly byside the welds... i share some pic when my evo II arrived and i do the install
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04-23-2013, 09:16 AM	#10
TheRuss Lieutenant 28 Rep 408 Posts Drives: BMW 135i Join Date: Sep 2012 Location: South West, UK iTrader: (0)	What's the difference with the Evo2? Just hoses instead of stock couplers?
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04-23-2013, 08:49 PM	#12
Johnny_M Private First Class 8 Rep 101 Posts Drives: Sold 135i 6MT SG Join Date: Oct 2010 Location: Irvine, CA iTrader: (0)	That is unfortunate Lifestyler. I'm glad to hear that you received great customer service from Wagner at least. I have a Wagner FMIC as well and it has been running strong and I've had no issues. I can't wait until Helix sees this though... __________________ // [Sold 08/16] 2009 135i SG 6MT \| Cobb \| Wagner FMIC \| MadDad \| OCC \| RB PCV \| MFactory LSD \| Forgestar F14 \| PSS \| ECS 2pc \| Ferodo \| Goodridge \| M bits \| Koni Sport \| BMW PS, PE, Side Skirts \| Rieger \| Blacklines //
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04-23-2013, 11:39 PM	#14
cooler2442 Brigadier General 480 Rep 4,154 Posts Drives: 1/18 Monte Carlo Blue E92 M3 Join Date: Apr 2011 Location: Los Angeles iTrader: (6) Garage List 2016 Porsche GT4 [0.00]	Great for Wagner to step up but this shouldn't have happened in the beginning. Seems like quality control just isn't there.
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04-24-2013, 06:30 AM	#15
RimasRS Colonel 85 Rep 2,438 Posts Drives: BMW X3 SD Join Date: Sep 2010 Location: Europe iTrader: (0)	........ 700 eur in europe for this???? ....
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04-24-2013, 08:25 AM	#17
Lifestyler Banned 115 Rep 320 Posts Drives: F80 m3 competition Join Date: Nov 2010 Location: Germany iTrader: (0)	the evo II is way bigger then the evo I ! the new FMIC is arrived today... i install it now ! post later some pics, so long guys
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04-24-2013, 08:43 AM	#18
TheRuss Lieutenant 28 Rep 408 Posts Drives: BMW 135i Join Date: Sep 2012 Location: South West, UK iTrader: (0)	Does it require any more cutting than the Evo1? They both look the same in the pics online!
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04-24-2013, 09:15 AM	#19
Cozy Major 111 Rep 1,487 Posts Drives: E82 135i Join Date: Mar 2011 Location: Surrey, England iTrader: (0)	This could be a one off, I hope so but their V1 downpipes also suffered some kind of cracking issue at the bracket if I remember rightly. Still, problems happen and it's more about the service you receive that counts in that case. I nearly bought this cooler but instead opted for an ETS which I hope will give me no issue.
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04-24-2013, 11:06 AM	#21
first350 Private 8 Rep 92 Posts Drives: 2016 F80 M3 Join Date: Feb 2013 Location: Seattle iTrader: (1)	would be interested to hear about their welding processes...the IC installation doesn't appear to put a lot of forces on the unit, so I wonder if they didn't pre/post-heat during the welding process; there's a lot of thermal stresses that can be introduced during welding. Only stress it needs to handle are pressure cycles from boost.
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04-24-2013, 11:45 AM	#22
TunedM2C Brigadier General 829 Rep 4,190 Posts Drives: 2016 LBB M2 Join Date: Jan 2008 Location: Earth iTrader: (2)	That's crazy. Maybe you received an early protype? Good thing they're replacing it.
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