Intercoolers

Sports FMIC Standard Kit Shown

(Full Kit includes FMIC, Diverter Valve Pipe, and Carbon Fiber Shrouding)

Introducing our new, long awaited Sports Series Front Mount Intercooler (FMIC) System, the ultimate intercooler solution for your 535i!  Our 535i intercooler was developed through development and testing with our 135i Time Attack Race Car.  With the scorching heat found on Southern California racetracks, we pushed our 135i Time Attack Race Car to the limits in 100+ degree weather on numerous occassions.

The heart of the ER Competition FMIC is the massive 18”x5.5"x6” (26.5”x5.5"x3” with end tanks) high density bar and plate intercooler core. It features 594 cubic inches of very efficient high density bar  & plate core (35% larger) versus the factory 425 cubic inches of less efficient tube & fin core.  Through extensive testing of different types of intercooler cores (tube & fin, bar & plate) we found that the high density bar and plate core to be the most efficient. Independent testing (all data & dynos shown below have been independently conducted by our customers) has shown that our FMIC is so efficient in cooling that it has cooled intake air temperatures (IAT) to almost ambient (outside) temperatures. We also did extensive testing on the proper size to use to effectively cool the hot charged air as well as fight off “heatsoaking” (when the intercooler cannot transfer heat away faster than the heat building up from the hot intake air). “Heatsoaking” is not an issue at all as shown by consistency of the IAT staying in the same temperature range throughout the WHOLE RPM powerband. Also our FMIC recovers so fast after a full throttle pull that once you shift, it recovers completely. This is why pull after pull, our FMIC does not “heatsoak”. Beat on it all day long and the IAT’s will consistently be near ambient temperatures. The other intercoolers may be adequate if you lived your life a ¼ mile at a time (with hours between runs to cool down), they will definitely “heatsoak” under harsher conditions like road racing where you’re at full throttle for at least 20 minutes. With numerous laps around our local racetracks in 100+ degree weather, heatsoak is not a problem on our 135i Time Attack race car.  With it's size and ability to support over 600hp, it is most likely the "last intercooler you will ever buy".

Factory Intercooler versus Competition Series FMIC

One of the most overlooked aspect of intercooler design is the intercooler end tank and piping.  Having shorter and less bends on the intercooler piping will promote better internal flow.  This helps in reducing turbo lag, increase throttle response and faster boost spool ups.  An intercooler end tank must be designed to channel and distribute air  coming in from the inlet efficiently throughout the intercooler core.  Our end tanks design has been revised numerous times to promote smooth internal air flow. The inlet pipe angle has been changed to provide a smooth entry into the end tank and removes an extra bend that the factory hoses have.  Rubber hosing expands under boost pressure.  This expansion disrupts internal flow and causes turbulence, all of which slow down airflow velocity (which causes slower boost spool up and decreased throttle response).  By replacing ALL the factory rubber hoses with hard piping, noticeable increases in boost spool up and faster throttle response can be seen.  That is why our FMIC kit comes with a new upper intercooler piping whereas brand FMIC kits do not.

Our Sports FMIC sits in the factory location underneath the radiator.  Why you ask?  The radiator fan and radiator shrouding extends from the radiator above, all the way down to the factory intercooler. By sitting our FMIC in the same location, we can take advantage of the radiator fan sitting behind the intercooler to pulling air through the intercooler core.  This makes for even greater efficiency, just like how the BMW engineers designed it to do.  Even with just a small fan on the dyno, intake air temperatures are still very low.  Also, by maintaining the factory configuration, we do not block airflow to the radiator at all.  The cooling system on the N54 engine is already at it's maximum capacity and we have seen overheating issues with both oil and coolant while racing.  By having an intercooler blocking half the airflow the the radiator will definitely not help it's cooling efficiency.

The Sports FMIC for the 535i is a very simple, "plug and play" installation.  Does not require trimming to the core support or bumper cover.  Only a small tab on the intercooler tray needs to be removed.

Evolution Racewerks Time Attack 135i.  439whp and 469lbs wtq.  ER Comp FMIC, ER Downpipes, ER Exhaust, Injen Intake, GIAC stage 2 software on Sunoco 104 gas.

Record Breaking 438whp and 450 lbs of torque. ER Comp FMIC, Catless Downpipe, Exhaust, Intake and JB3 on 100 Octane.

384 whp and 425lbs of Torque. ER Comp FMIC, Catless Downpipes, Exhaust, Intake and JB3 on 93 Pump Gas. 365whp and 411lbs of Torque with 91 Pump Gas.

Polished Finish

Type III Hard Anodize Black Finish

We also offer our intercoolers in any color of the rainbow you want (special order) and is available in only Type II Anodizing (asthetics).  Brush (or plain) finish is also available.

Shown in Polish Finish	BASIC KIT The Basic Kit consists of the intercooler assembly, lower intercooler piping, turbocharger piping, silicone hump hoses and t-bolt clamps.  Everything you need to install the FMIC on your car and is what is typically included in most FMIC kits out in the market.
Shown in Type III Hard Anodize Black Finish	STANDARD KIT The Standard Kit consists of everything included in the Basic Kit but adds the Diverter Valve Charge Pipe.  The Diverter Valve Charge Pipe allows easy upgrades of the Diverter Valve or Blow Off Valves. Increase throttle response as well as decrease turbo lag are the benefits of the new Diverter Valve Charge Pipe.  For more information about the Diverter Valve Charge Pipe, click here.

Forge Diverter Valve Upgrade Kit TIAL Q Blow Off Valve

DIVERTER VALVE & BLOW OFF VALVE OPTIONS Diverter Valve & Blow off Valve Option can be added to the Standard Kits.  BOV flange will be welded to the diverter valve pipe instead of the factory style diverter valve flanges.  We are now carrying the Forge Diverter Valve Upgrade Kits.  For more information about the Forge Diverter Valve Upgrade Kit, click here. You now have 3 different blow off valves to choose from: TIAL 50mm Q Blow Off Valve, Synapse Synchronic Blow Off Valve and HKS Super Sequential Blow Off Valve. TIAL BOV Option: Black color is standard.  For other colors, please specify.  Available in black, red, blue, polished silver and purple. Synapse Synchronic Blow Off Valve The new HKS Super Sequential Blow Off Valve 4

METHANOL INJECTOR BUNGS With the popularity of methanol injection systems, we have added the option of having methanol injector bungs welded to our diverter valve charge pipe.  This allows quick and easy installation of methanol injectors that are used in methanol injection systems.  You have the option of adding 1 or 2 methanol injector bungs.

FREE GIFT!!!	FREE GIFT!!!
FREE GIFT!!!	Free Gift with purchase!

Introducing our new Diverter Valve Charge Pipe for the BMW 535i with the N54 Twin Turbo Engine. 

Polish Finish Shown

Type III Hard Anodize Black with 1 Methanol Bung Shown

Ease of Installation: (1 Easy, 5 Hard) 1

Key Features:

• Increase throttle response and decreases turbo lag.
• Compatible with factory diverter valves or aftermarket factory style diverter valves.
• Lightweight High Grade 6061 Aluminum Piping.
• Throttle body matched 3" piping.
• Retains factory style o-ring throttle body lock flange.  Precision CNC machined throttle body flange ensures leak free connection to throttle body.  Quick and easy connection and disconnection to throttle body.  Ideal connection compared to the silicone hose and hose clamp connection found in all other aftermarket diverter valve upgrade pipes available in the marketplace.
• Precision CNC machined MAP sensor flange ensures leak free connection.
• Diverter Valve Charge Pipe features beaded ends and T-bolt clamps to prevent intercooler piping from coming off from boost.
• Factory diverter valve sound baffle, which causes turbulence in the factory pipe, is removed.
• Optional Type III Hard Black Anodizing (for stealth and OEM look).  Hard anodizing helps improve durability of intercooler piping.  Resists bent or dented piping.
• Includes all hardware for complete installation.
• Optional TIAL Q Blow Off Valve available in 5 different colors (black, polished silver, red, blue and purple).
• Optional Synapse Synchronic Blow Off Valve now available!!!
• Optional HKS Super Sequential Blow Off Valve now available!!!
• Limited Lifetime Warranty.

Again, another parts development directly from our 135i Time Attack racing program.  The factory diverter valves were causing an issue of not being able to hold up against the rigors of high boost application, therefore they needed to be replaced.  Thus attention was brough to the factory diverter valve pipe and the need to optimize for maximum performance on a race car facilitated the need for a new pipe to be built.  Often ignored, charged intake airflow characteristics greatly affect throttle response, turbo lag and ultimately maximum power potential.  Smooth bends and minimal obstructions are ideal.  This is not the case with the factory diverter valve charge pipe.  On the factory diverter valve chargepipe features a sound baffle for the diverter valves.  This sound baffle is connected on the side of the factory diverter valve  charge pipe which splits airflow.  This causes turbulence inside the pipe which slows the charge intake air velocity (speed of the air traveling inside the pipe).  By removing this turbulence (by eliminating the factory diverter valve sound baffle), increased throttle response, decrease turbo lag and ultimately higher maximum power potential can be realized.  Our Diverter Valve  Charge Pipe eliminates this sound baffle and thus eliminating the unneccesary turbulence in the diverter valve pipe, keeping charge intake air velocity at it's maximum.  Apparrently, BMW thought the same thing as later model (2009-10) did not come with this baffle.

Charge Pipe with outlet for DV Sound Baffle

Later model Charge pipe with no outlet for DV Sound Baffle

Since one of the reasons for changing out the factory diverter valves was to prevent boost leaks (from prematurely opening on high boost), causing boost leaks while upgrading the diverter valve would be counterproductive.  During our research and development, the connection at the throttle body was looked over very carefully.  The factory diverter valve is connected to the throttle body using an o-ring inside the throttle body flange which is locked in place by a c-clip, which works very well.  It also make removal/installation quick and easy.  Our testing had shown it could hold quite a bit of boost.  During our testing, we had pressure tested this connection up to 25 PSI.  The reason why we stopped at 25 PSI was because at 25 PSI, one of the intake pipes on the turbo blew off and we could not test any higher.  Hoewver, we were confident that it would easily hold over 25 PSI as the throttle body flange showed no signs of failing.  Also, keep in mind, this type of connection is used throughout the engine, in many crutial areas like the coolant radiator system as well as the clutch system.  If BMW did not believe in the durability of this type of connection, they would not use it in such important areas.

Many of our competitors use a silicone hose connection for the throttle body connection.  It is not designed for a silicone hose connection which is used by all the other brand diverter valve pipe upgrades in the market.  The throttle body lip is too short and there are no "beads" to prevent the silicone hose from blowing off under boost.  Even though it is the easiest way to  "rig" together, it is not ideal.  The best way to connect the new diverter valve pipe to the throttle body is to replicate the same connection which we did.  We spent a lot of resources developing and manufacturing this factory style connection for this reason.

Precision CNC machined throttle body flange ensures boost leak free connection

The same issue came with the MAP sensor.  The MAP sensor seals to the factory diverter valve pipe via a o-ring on the sensor itself.  Having a hole in a silicone hose will definitely cause a boost leak as it will not properly seal.  Therefore, again we CNC machined our own replica MAP sensor flange that utilizes the same factory o-ring seal.

Precision CNC Machined MAP Sensor Flange ensures boost leak free connection

MAP Sensor attached to the flange.

Charge Pipe Finishes:

The Diverter Valve Charge Pipe is available in the same 3 finish options as our intercoolers.  It is available in a brushed (plain) or mirror polish finish standard.  It is also available in our Type III Hard Black Anodizing for the guys that want the stealthy, factory look.  An added benefit of the Type III Hard Black Anodizing is that it hardens the aluminum piping and makes it more durable against damage (like dropping the pipe).

We also offer our Diverter Valve Charge Pipe in any anodizing color of the rainbow you want (special order) and is available in only Type II Anodizing (asthetics).  It is available as a special order item and is not stock. 

Brush (or plain) finish is also available.

1/8" NPT Bungs (For Methanol or Nitrous Injectors):

With the popularity of methanol injection systems and nitrous systems, we have added the option of having a 1/8" NPT  threaded bung (for methanol or nos injectors) welded to our diverter valve charge pipe.  This allows quick and easy installation of methanol/nitrous injectors that are used in methanol injection systems and nitrous systems.  You have the option of adding 1 or 2 injector bungs.  Each 1/8" NPT bung will come with a plug so that you can run with or without the methanol injector.  This is perfect for those who do not have the Methanol Injection yet but plan to do so in the future.

1/8" NPT Bungs (for methanol or nitrious injectors).  Each bung comes with a plug (shown).

Blow Off Valves (BOV):

The standard option for our Diverter Valve Upgrade Pipe is designed for either the factory diverter valves or aftermarket "factory style" diverter valve.  Also available is the TIAL Blow Off Valve option which utilizes the TIAL Q Blow Off Valve (BOV).  The TIAL Q BOV features a large 50mm (2") valve to quickly discharged built up boost pressure.  Since the TIAL Q BOV vents to the atmosphere which causes no restriction to venting boost, it reacts faster than recirculated diverter valves.  The internal valve spring can be changed out to different spring rates which allow adjustability.  This allows versatility as it allows you to increase the spring pressure in the future for when you run higher boost levels.  Therefore, it eliminates the need to purchase another BOV or diverter valve if you increase boost levels.  Essentially, this is the last blow off valve you will ever buy.  The TIAL Q BOV is available in 6 different colors: black, polished silver, red, blue and purple.  The black color option is standard.  If you want any other color, please specify when ordering.

Tial Q Blow Off Valve

Available in Black, Polished Silver, Red, Blue and Purple

HKS Super Sequential Blow Off Valve (SSQV) 4 Blow Off Valve (BOV).  You can order it with just  the HKS BOV flange welded on or with the SSQV BOV included.  We include only genuine HKS SSQV 4 (no oversea knock offs like you see on E-bay).  The HKS BOV is designed to make a loud sound when releasing.  Choose this option if you want all your neighbors to hear you coming down the street.

HKS SSQV 4 Blow Off Valve

HKS SQV Racing Blow Off Valve is a larger version of the HKS SSQV 4.  It features a 51mm valve to release more pressure.  You can order it with just the HKS Racing BOV flange welded on or with the SQV Racing BOV included.  We include only genuine HKS SQV Racing (no oversea knock offs like you see on E-bay).  

HKS SQV Racing Blow Off Valve

We can also build our Diverter Valve Charge Pipe to utilize any BOV or diverter valve you desire.  Love the way the Greddy BOV sounds?  No problem, we can weld any BOV flange on our Diverter Valve Charge Pipe so that you can utilize any BOV or diverter valve you want.  Due to the fact that there are so many options for BOV's and diverter valves, it will be impossible for us to stock these options.  Therefore, it is available only as a special order and will be built to order.  Contact any of our authorized dealers for more information on how to order this.  Only the TIAL, Synapse and HKS BOVs are kept in stock.

Options:

Add a replacement throttle body C-Clip.  If your factory throttle body c-clip is lost or broken, you will need to order this.  For more information about the Throttle Body C-Clip Replacement, click here.

CAUTION: This product is intended for OFF ROAD USE ONLY. Not legal for use on pollution controlled vechiles upon public road/highways.   THIS PRODUCT IS FOR SALE FOR ALL 49 STATES EXCLUDING CALIFORNIA. 

THIS ITEM IS NOT FOR SALE, INSTALLATION, OR USE ON LICENSED VEHILES IN THE STATE OF CALIFORNIA. 

 The item is for sale for international customers without restriction.

Free Gift with purchase!

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