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      03-30-2023, 10:47 AM   #1
B21
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Your specialist subject: the life and times of E89 intercoolers

Another B21 shaped hole I dug myself into.

I fitted a Wagner Evo 1 FMIC to replace the stock FMIC on my 20i when I remapped it past 300bhp.

It turns out that the 18i/20i/28i FMIC is the same as the 35i/35is FMIC.

Prior to selling the car I re-installed the OE FMIC and transfered the Wagner Evo 1 FMIC to the 35is..all well and with that went onto record 400 bhp on my trusty dyno.

Fast forward on to the uprated TTE500 turbo upgrade plan..whih called for uprated inlet /outlet plumbing from 1.75" to 2"

Sudden dawning that both the relative sizing and the type of connectors was going to be a problem.

The OE connectors to the OE FMIC are push in and circlip..the aftermarket turbos, the outlet pipes and charge pipes are all push over with hose clamps.

I therefore was left with an imponderable when we came to fit said plumbing..how and if I could connect the Evo1 with OE style connectors to the new larger 2" slip over plumbing and uprated VTT turbo outlet pipes and new VSRF charge pipe.

Given that I'm using a local garage's 4 post lift and helper I didn't want to get stuck with an issue that either couldn't be resolved or would take time.

The issue is the dissimilar sizes of the external diameter of the Evo 1 FMIC and the plumbing around it..about 12-15 mm difference and the need also for flexible couplings and high temperature (greater than 150c) and high pressures (more than 2 bar) required.

In the end I just opened up the wallet and bought an Evo 2 which is designed for the job..so all plumbing lines up, they supply the correct hoses and voila..problem solved..

There is a small performance advantage of the Evo 2 as a tube and fin construction vs the Evo 1 which bar and plate.

First world problems..

Pictures show relevant story and stock 35i FMIC for comparison.
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Much modified 2011 Atacama Yellow 35is…previously a much modified 2012 Atacama Yellow 20i MSport
Change history here… https://www.dropbox.com/s/8h1vabklgz...0List.pdf?dl=0
Build thread here… https://z4-forum.com/forum/viewtopic.php?t=131886
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      03-30-2023, 02:12 PM   #2
KennyP
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Isnt evo 1 like meant for cars with boltons and stage 2 remaps max?
The moment you get hybrid turbos you should upgrade to a bigger FMIC anyway... like vrsf 7" or yes this EVO 2 kit you got..
I have had my eyes on these evo 2-s for some time.. They are pricy but my idea was that if some day my turbos get to the point of needing replacement i would surely not fit stock turbos back and would upgrade them to something with more potential. With evo2 i wouldnt have to upgrade my intercooler again and keep using it. And i love that this kit comes with all the necessary piping meant for e89. Also OEM intercooler quickconnects are said to be restrictive anyway as the inner diameter of the piping is smaller at the connection point.

And Wagner used to offer 2 versions of the EVO2:
1."Performance" which was bar and plate... meant more for street use.. as it had more resistance to heat soak but when it got heatsoaked took longer to cool down... great for odd pulls on the street... it was also a bit cheaper option

2. "Competition" which is tube and fin... this one was meant more for track use.. as its supposed to heatsoak a bit faster? but also cool down faster... So its supposed to be better for continous hammering at the track..
Also Competition variant is alot lighter due to tube and fin construction. And those big intercoolers do get heavy.

After a while Wagner stopped offering the Performace variant of EVO2 and now only the more expensive "Competition" version remains. At least i havent seen Performance version available anywhere for a while now.
Great purchase!
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2009 35i DCT Havana brown with ivory white interior. Mods: Cobb stage 1+FMIC, Wagner EVO1 FMIC, BMS DCI, KW V3 suspension, M3 front control arms, Hardrace RTAB, Michelin Pilot Sport 4S tires.
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      03-31-2023, 03:39 AM   #3
B21
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Given our climate here I’d have stuck with the Evo 1….if you look at Wagner’s published data there’s not a big difference between the Evo 1 and Evo 2 as a FMIC..the Evo 2 just edges out the Evo 1…the Evo 1 is a big improvement over the OE FMIC.

As you say maybe you get better flow and adds a few ponies..I’ll never know as the dyno runs will be done with all the uprated plumbing..we will see how restrictive the stock airbox will be on dyno day.

The big issue is the complete incompatibility between the uprated turbo outlet pipes and charge pipe and the OE proprietary connectors..

So problem solved..phew..
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Much modified 2011 Atacama Yellow 35is…previously a much modified 2012 Atacama Yellow 20i MSport
Change history here… https://www.dropbox.com/s/8h1vabklgz...0List.pdf?dl=0
Build thread here… https://z4-forum.com/forum/viewtopic.php?t=131886
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