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      09-25-2018, 08:57 AM   #1
drwillb
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Pothole took out my ER Oil Cooler

Coming out of Home Depot parking lot this morning, heavy rain, rolling at crawl pace to get onto highway. BAM! Dropped into DEEP pothole filled with water. Really wasn't a hit, just dropped into it.

Get on highway, oil pressure light comes on, reduced power sets in. I was on a U-turn on ramp so I just coasted to a stop on the highway and called AAA. Didn't get out of the car (I thought it was oil pump and oil was at max 30 minutes prior to this) until AAA got there. That's when I saw the oily mess.

Looks like the low hanging hoses on the cooler got crushed or the cooler itself burst. The car was taken directly to my local dealer (just 1.5 mile away). I explained everything to the service advisor, including the laundry list of aftermarket parts on the car. He said not to worry they'll work with me on this.

Edit: the impact cracked the cooler where at the hose fitting connection, the hose is fine

The folks at ER had a replacement radiator in stock (black anodized). Hooked me up with overnight shipping. I'll be on the road tomorrow.
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2012 135i Mods: air scoops, CP, K&N filter, PS1, ADE FMIC, BMW PE, JB4, 1M front body, full M3 suspension front and rear, M3 brakes front and rear, M3 rear subframe and LSD
Owned so far: 88 M3 x 2, 95 325is, 95 M3 x 2, 06 Mini Cooper S, 08 335 xi, 09 Z4 35i, 01 M3, 12 135i

Last edited by drwillb; 09-25-2018 at 06:05 PM..
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      09-25-2018, 10:32 AM   #2
optigrab
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geesh do you have the single or dual?

good luck! let us know how it goes
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      09-25-2018, 10:47 AM   #3
bbnks2
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Sucks but it happens... This is not an "ER oil cooler fail" but rather a "driver fail."

This is what my car looked like last week when I had a "cheap Chinese nylon braided AN oil line fail:"

[IMG]https://bmw.***********.com/attachments/20180920_141715-jpg.15981/[/IMG]

[IMG]https://bmw.***********.com/attachments/20180920_180149-jpg.15982/[/IMG]

Replace *** with "spool" + "street"
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      09-25-2018, 11:18 AM   #4
drwillb
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I have the double oil cooler setup with the expensive braided SS lines.

True not an ER problem other than the dumb setup with the oil lines on the bottom of the coolers instead of the top or side.

It was raining heavily this morning and the hole was filled with water, looked like all the other wet pavement around it: Ghost Hole


PS: I changed the post title because I don't want to sound like I'm bashing on ER
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2012 135i Mods: air scoops, CP, K&N filter, PS1, ADE FMIC, BMW PE, JB4, 1M front body, full M3 suspension front and rear, M3 brakes front and rear, M3 rear subframe and LSD
Owned so far: 88 M3 x 2, 95 325is, 95 M3 x 2, 06 Mini Cooper S, 08 335 xi, 09 Z4 35i, 01 M3, 12 135i
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      09-25-2018, 02:38 PM   #5
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Quote:
Originally Posted by bbnks2 View Post
Sucks but it happens... This is not an "ER oil cooler fail" but rather a "driver fail."

This is what my car looked like last week when I had a "cheap Chinese nylon braided AN oil line fail:"

[IMG]https://bmw.***********.com/attachments/20180920_141715-jpg.15981/[/IMG]

[IMG]https://bmw.***********.com/attachments/20180920_180149-jpg.15982/[/IMG]

Replace *** with "spool" + "street"
Which eBay intercooler did you get? How many miles on it before it burst?
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      09-25-2018, 06:05 PM   #6
drwillb
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the impact cracked the cooler where at the hose fitting connection, the hose is fine

The folks at ER had a replacement radiator in stock (black anodized). Hooked me up with overnight shipping. I'll be on the road tomorrow.
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2012 135i Mods: air scoops, CP, K&N filter, PS1, ADE FMIC, BMW PE, JB4, 1M front body, full M3 suspension front and rear, M3 brakes front and rear, M3 rear subframe and LSD
Owned so far: 88 M3 x 2, 95 325is, 95 M3 x 2, 06 Mini Cooper S, 08 335 xi, 09 Z4 35i, 01 M3, 12 135i
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      09-26-2018, 07:55 AM   #7
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Quote:
Originally Posted by drwillb View Post
I have the double oil cooler setup with the expensive braided SS lines.

True not an ER problem other than the dumb setup with the oil lines on the bottom of the coolers instead of the top or side.

It was raining heavily this morning and the hole was filled with water, looked like all the other wet pavement around it: Ghost Hole


PS: I changed the post title because I don't want to sound like I'm bashing on ER
The oil cooler lines face down so that the oil cooler can be drained easily if need be (like during an oil change).
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      09-26-2018, 08:04 AM   #8
bbnks2
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Quote:
Originally Posted by houtan View Post
Which eBay intercooler did you get? How many miles on it before it burst?
I bought a cheap $125 28 row oil cooler kit on EBAY from "G-PLUS" years ago that I put on my 128i (https://www.ebay.com/itm/GPLUS-For-C...8AAOSw6zNbiQhw
). Need to make your own mount though ( i had posted a diy on this back then). I actually just put it on my 135i and it's still fine. Those oil lines are better quality than the crap I just had an issue with.

I had bought 3ft of AN10 hose from "goodqualitycarparts" to make an oil line for an Accusump. That is the hose that burst open. I should've known better then to try to run it. You could just feel how flimsy it was and the metal mesh was already popping out of the hose before I even put pressure through the line.

I hosted the pics:

Last edited by bbnks2; 09-26-2018 at 09:25 AM..
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      09-26-2018, 10:47 AM   #9
drwillb
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Quote:
Originally Posted by bbnks2 View Post
The oil cooler lines face down so that the oil cooler can be drained easily if need be (like during an oil change).
Putting the connection at the lower inside corner would achieve similar results.

Just saying...
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Owned so far: 88 M3 x 2, 95 325is, 95 M3 x 2, 06 Mini Cooper S, 08 335 xi, 09 Z4 35i, 01 M3, 12 135i
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      09-26-2018, 11:16 AM   #10
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Quote:
Originally Posted by drwillb View Post
Putting the connection at the lower inside corner would achieve similar results.

Just saying...
Yes it would, but, the width of the oil cooler + fittings would no longer fit within the bumper opening. I've tried it. It also means the oil cooler won't be centered in the path of airflow. Worse and worser.

Sucks you got oil everywhere. I can relate as you can see which is why I posted. I just couldn't agree with you inferring this was ER's fault. You hit something lol. You know what else is easy to break if you hit something? your oil pan... Would you blame BMW for putting the oil pan on the bottom of the car if that is what had cracked?
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      11-19-2018, 08:05 AM   #11
drwillb
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Follow up to the story: now the left side cooler sprung a leak.

The leak is on the back side of the core somewhere and it's small but big enough to blow a quart in a week. I would think it's not related to a rock since it's on the back and I've got the supplied louvered grill from ER in place.

Great.
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Owned so far: 88 M3 x 2, 95 325is, 95 M3 x 2, 06 Mini Cooper S, 08 335 xi, 09 Z4 35i, 01 M3, 12 135i
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      11-19-2018, 02:40 PM   #12
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Had a similar issue with my ER oil cooler where the male AN fitting was welded to the core. I replaced the ER core with a Setrab core which is just as wide and about 1” shorter. I had to cut the side mounting tabs off the Setrab unit and fabricate a mounting bracket on the top and bottom of the unit out of aluminum L-beam. The Setrab unit is incredibly durable, performs better, and you gain about 1 1/4” clearance at the bottom when you factor in Setrab’s 90 degree fitting? You can find pictures of the setup on my profile page. Keep in mind that the carbon fiber “box” that the cooler is sitting in is the same size as ER’s aluminum box.
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      11-19-2018, 03:50 PM   #13
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Pig Farmer, your setup looks very nice. I'll keep the Setrab option open for next time around. Do you remember which model unit you used?

I had bought some mesh to cover the air hole in the bumper since the radiators are sitting exposed behind a huge opening. However, I never got around to installing it.

Here it is, a pretty good match for the factory mesh in the center of the bumper:

https://www.ebay.com/itm/5-Black-Hon...ccFC:rk:3:pf:0

I've already ordered the replacement ER cooler and you can be sure I'll be putting that mesh on this weekend.

I also picked up two -10 elbows so I can bypass either cooler by joining the input and output hoses. I was always afraid that I'd lose a cooler to flying debris on the track when far from home. Now I'll have mesh and my backup/bypass, just in case.
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2012 135i Mods: air scoops, CP, K&N filter, PS1, ADE FMIC, BMW PE, JB4, 1M front body, full M3 suspension front and rear, M3 brakes front and rear, M3 rear subframe and LSD
Owned so far: 88 M3 x 2, 95 325is, 95 M3 x 2, 06 Mini Cooper S, 08 335 xi, 09 Z4 35i, 01 M3, 12 135i
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      11-21-2018, 08:47 AM   #14
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Thats a pretty good idea with the mesh..

Mike
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      11-22-2018, 05:36 PM   #15
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Putting a mesh really sounds a good idea for extra protection.
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      11-25-2018, 07:58 PM   #16
drwillb
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Seems like a miracle but I actually got most of my car agenda accomplished this weekend (LPFP and pressure regulator next weekend).

The oil cooler arrived on time and I got to work replacing it, putting mesh over the huge duct opening, and getting the factory air curtain duct (stock 1M bumper) in place. This last piece would probably fit with no trimming of the ER metal ducting for oil cooler but things looked just a bit too tight. I got the Dremel out and trimmed some metal to loosen things up.

The factory bumper has no provision for attaching the mesh with clips or any hardware since this is normal just a huge opening leading to factory ducts for the coolers on each side (1M). I was running out of time so I resorted to holes in the bumper material and zip ties. Not ideal, but works fast and easy and doesn't stick out like a sore thumb.

Here it is:
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Owned so far: 88 M3 x 2, 95 325is, 95 M3 x 2, 06 Mini Cooper S, 08 335 xi, 09 Z4 35i, 01 M3, 12 135i
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      11-25-2018, 09:25 PM   #17
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Looking great man, well done!
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