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      08-15-2020, 08:28 AM   #1
CarJunkie
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Managed to break my ER charge pipe at the factory fail point!

Managed to break my ER charge pipe at the factory fail point!


I had a loss of power during my last session at the track the other day and pulled a 30FF code, loss of boost. I didn't have time to investigate it before coming home, but everything looked OK from above on the driver side, but with stock air box I couldn't see the charge pipe/TB attachment. I have at ER charge pipe. I assumed it was an intercooler attachment. Well, when I tugged on the diverter valves this morning to make sure they were tight, my charge pipe was flopping around. My aluminum Evolution Raceworks charge pipe apparently broke at the factory chargepipe's weak spot even though it's aluminum. Has anyone else ever broken one of these?
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      08-15-2020, 08:50 AM   #2
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Yikes!! That's a bit disheartening since I also have an ER chargepipe.
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      08-15-2020, 09:07 AM   #3
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Quote:
Originally Posted by a4nut View Post
Yikes!! That's a bit disheartening since I also have an ER chargepipe.
I am running a tune and this was probably the 30th+ track day since it was installed. I am going to replace it with one that uses a flexible silicone hose attachment because I think the rigid attachment is the issue. I chose the ER pipe because it used the factory attachment method, and that was probably a mistake. I believe most of the other aftermarket units use a short segment of silicone hose with two clamps to attach to the throttle body.
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      08-15-2020, 12:15 PM   #4
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Worn motor and/or transmission mounts?
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      08-15-2020, 12:28 PM   #5
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Quote:
Originally Posted by E30 Racer View Post
Worn motor and/or transmission mounts?
That must play a role. I am going to address that also. I got some feedback frim the FB N5x group that this is a common failure.

Ordered replacement from Burger. Car was already going to ADE this week for custom tune and oil cooler upgrade so Andy will replace the CP. I may just have him install his motor mounts also.
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      08-15-2020, 12:32 PM   #6
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I've been considering E46 M3 trans mounts for a while now as a no compromise upgrade. Wonder if they'd be enough for you? Not sure whose engine mounts I'd use...easy to create a buzz bomb with the wrong choice.
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      08-15-2020, 01:17 PM   #7
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Quote:
Originally Posted by E30 Racer View Post
I've been considering E46 M3 trans mounts for a while now as a no compromise upgrade. Wonder if they'd be enough for you? Not sure whose engine mounts I'd use...easy to create a buzz bomb with the wrong choice.
According to Andy at ADE, stiffer trans mounts add a lot more vibration than motor mounts.
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      08-15-2020, 07:44 PM   #8
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Strongly recommend RE trans mounts and OEM engine mounts with the VTT bmw racing style reinforcement plates.

I'd bet my paycheck on worn mounts being the cause.

Is the throttle body ok?
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      08-16-2020, 02:55 PM   #9
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I've never really thought about this as a potential failure point but given how rigid that connection point is I guess it's not surprising that it could fail over time in the context of worn engine mounts etc.

Aftermarket CP manufacturers advertise that reusing the OEM CP-throttle body C-clip connection is most secure but apparently only kind of.

I can see using silicone couplers accommodating more movement but I have to wonder how often those couplers will separate from the throttle body with added boost. I have the feeling that it would just be trading one failure mode for another.
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      08-16-2020, 08:12 PM   #10
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Quote:
Originally Posted by ShocknAwe View Post
Strongly recommend RE trans mounts and OEM engine mounts with the VTT bmw racing style reinforcement plates.

I'd bet my paycheck on worn mounts being the cause.

Is the throttle body ok?
From what I can see, TB is fine. I am planning motor mounts, and will do a little more research on trans mounts.
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      08-17-2020, 03:55 AM   #11
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I have been running ER charge pipes since 2012 on my N54's, just out of curiosity, did you use the mounting point with the T20/T30 torx?
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      08-17-2020, 08:08 AM   #12
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Quote:
Originally Posted by Boost3d_1M View Post
I have been running ER charge pipes since 2012 on my N54's, just out of curiosity, did you use the mounting point with the T20/T30 torx?
Yes, and I've noticed that other brands (Cobb, Phoenix) don't even have a flange there.
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      08-17-2020, 06:49 PM   #13
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Quote:
Originally Posted by CarJunkie View Post
According to Andy at ADE, stiffer trans mounts add a lot more vibration than motor mounts.
This has definitely been my experience, albeit with different platforms. My autox E30 has poly engine mounts and RE rubber trans mounts. NVH is entirely streetable. Years ago, I installed UUC poly trans mounts on an E46 with stock engine mounts. NVH was horrible...buzz bomb city. I drove the car 4 blocks, turned around, and pulled them off.
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      08-17-2020, 06:55 PM   #14
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Quote:
Originally Posted by E30 Racer View Post
Quote:
Originally Posted by CarJunkie View Post
Quote:
Originally Posted by E30 Racer View Post
I've been considering E46 M3 trans mounts for a while now as a no compromise upgrade. Wonder if they'd be enough for you? Not sure whose engine mounts I'd use...easy to create a buzz bomb with the wrong choice.
According to Andy at ADE, stiffer trans mounts add a lot more vibration than motor mounts.
Quote:
Originally Posted by CarJunkie View Post
Quote:
Originally Posted by E30 Racer View Post
I've been considering E46 M3 trans mounts for a while now as a no compromise upgrade. Wonder if they'd be enough for you? Not sure whose engine mounts I'd use...easy to create a buzz bomb with the wrong choice.
According to Andy at ADE, stiffer trans mounts add a lot more vibration than motor mounts.
This has definitely been my experience, albeit with different platforms. My autox E30 has poly engine mounts and RE rubber trans mounts. NVH is entirely streetable. Years ago, I installed UUC poly trans mounts on an E46 with stock engine mounts. NVH was horrible...buzz bomb city. I drove the car 4 blocks, turned around, and pulled them off.
I think the Rogue trans mounts would be reasonable given their construction. I may still do that, but want to get a sense of what each one does with regard to NVH. The motor mounts seem critical to preventing the excessive engine movement which turns the charge pipe into a lever.
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      08-18-2020, 03:03 AM   #15
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Quote:
Originally Posted by CarJunkie View Post
Yes, and I've noticed that other brands (Cobb, Phoenix) don't even have a flange there.
I think this was the biggest differentiator between the ER charge pipes and most other brands, was utilizing that factory mount point that actually held the pipe in place and prevented it from blowing off easily. As you mention in a later post, unfortunately it does look like it became a lever . Makes one wonder if it is the motor mount flex causing the stock plastic pipe to break, or is it because of additional boost etc
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      08-18-2020, 08:59 PM   #16
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Dropped off the car to AD Engineering this afternoon. New charge pipe from Burger will arrive Thursday. The car will get a larger oil cooler with bigger lines and an external oil thermostat (that work was already planned) and he will swap the motor mounts for his which have a longitudinal design. I saw them installed in a 3series chassis and they are stout. That will solve the motor movement issue. I may do RE trans mounts this next offseason.

After the CP is replaced, he will do a custom dyno tune, which was also planned for this week. I hope to have the beast back Friday and give it some hell this weekend.
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