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2010 2011 BMW 5 Series Forum F10 F10 Technical Topics Engine, Transmission, Exhaust, Drivetrain, ECU Software Modifications G Plus Intercooler Install DIY
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      03-22-2019, 09:01 PM   #1
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So last week I ordered a G Plus intercooler after my IATs started to climb to the 130s. I live in Az and I need to make sure my car stays cool during the summer. At first I was going to order a Wagner and then I heard about the VRSF Intercooler coming out and after all the back and forth Ive heard about everyone going through I just went ahead and ordered this one.

Let me start out with "Its a tight fit" is an under statement but it eventually does. Some members were asking me for some comparison pics and fin per inch pics so here are those. Ohh and my intercooler did not come with brackets so in this DIY I show you how I made mine for less than 10 dollars if you have all the tools.

[IMG]https://ibb.co/X5j32Tt[/IMG]

[IMG]https://i.postimg.cc/y8XgKtPM/IMG-1494.jpg[/IMG]


[IMG]https://i.postimg.cc/J0k5M8PN/IMG-1512.jpg[/IMG]

I started with putting my car on drive up lifts
[IMG]https://i.postimg.cc/bYs6mcHN/IMG-1498.jpg[/IMG]

Then once it was up on there I began removing the under belly pan/cover of the intercooler and radiator with an 8mm socket, 4 connected to the bumper and then 6 or so to the under belly cover.

[IMG]https://i.postimg.cc/k4DBx4mC/IMG-1499.jpg[/IMG]

[IMG]https://i.postimg.cc/XvjZYL1p/IMG-1500.jpg[/IMG]

After removing that I removed the Intercooler securing tray with a Torx bit T25. There are only two screws for that, and these are the ones you will be using with your intercooler brackets.

[IMG]https://i.postimg.cc/wjd0xtK7/IMG-1505.jpg[/IMG]

I would probably wear safety glasses during this cause there was so much dust and debris around this area dirt and bugs carcasses were constantly falling in my eyes. It was annoying.

Now go ahead and use a large flat head screw driver to unsecure the hose clips. Just pry the clip away from the hose they do not come off they stay attached but once lifted up it will loosen the clip at the sides as well.


[IMG]https://i.postimg.cc/ZKNwh8MG/IMG-1504.jpg[/IMG]


Once you've done this to both hoses, you will need to push the intercooler towards the front of the car so the tabs on the intercooler have a fee path so the intercooler can slide out.


[IMG]https://i.postimg.cc/HWc2Q0dr/IMG-1509.jpg[/IMG]


It will take some wiggling but the stock intercooler comes out pretty easily.

Now comes the hard part. Start sliding the G plus intercooler into the location you pulled the stock one from. The oil lines tend to get in the way so I would try to zip tie them up or out of the way or I was able to position them so they didn't interfere with what I was doing.

I had a hard time getting the intercooler in both sides at the same time. The driver side was the easiest. But once you get that side in don't attach the hose yet. The passenger side is very very difficult and takes some persuasion. Also make sure before you get the intercooler all the way into place you have the electric fan on the inside of holding brackets or you will be trying to pull the intercooler back down enough to get that into place.


I had a very difficult time getting my hoses attached at this point the driver side attached easily but my passenger side was a real pain in the rear. But after some persuading I was eventually able to get it attached and had the intercooler attached and in place for me to make the brackets.


[IMG]https://i.postimg.cc/PqVWDJ7b/IMG-1517.jpg[/IMG]

Now some of you may laugh but instead of using just flat bar I went this route. I purchase two 90 degree shelf holders. They are powder coated black and have a clean 90 degree bend in them already.

[IMG]https://i.postimg.cc/XNRgxZYQ/IMG-1513.jpg[/IMG]

So it just took me to drill a few holes and a small cut to bend the top of the tab so that it was parallel with the mounting surface of the car. As well as bending the 90 degree just a little out. Youll have to do a few mock up trials to figure what degree you need but mine looked something like this. I will eventually tig weld the brackets up where I cut the tab to bend it but didn't have access to my buddies welder today.


[IMG]https://i.postimg.cc/T3GJMZmb/IMG-1514.jpg[/IMG]


[IMG]https://i.postimg.cc/2SwFz2FK/IMG-1516.jpg[/IMG]

Now technically since you have to cut and drill on the piece the whole powder coated part doesn't really matter and once I weld the bracket up Ill have to clean the powder coat off so that whole part was just in hopes that it was going to be a straight 90 degree bend down to the intercooler but it was not that simple one mine. hence the cut and bend of the bracket. Even tho their brackets appear to be that way and other DIY post show that mine was not that way for some reason.


Once everything is installed and tighten all you have to do is button up everything and pray you did everything right and you have no boost leaks lol


I went and recoded some logs with the ambient air being 75 degrees and my IATs never saw over 91 degrees.


Before Log

[IMG]https://i.postimg.cc/ZnjcRH6H/Before-Log.png[/IMG]


After Log

[IMG]https://i.postimg.cc/4yXPsqHn/After-Log.png[/IMG]

Hope this helps everyone and feel free to ask me any questions you guys have.
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Last edited by InHousePerformance; 03-22-2019 at 09:41 PM..
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      03-22-2019, 09:23 PM   #2
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Outstanding! Thank you for the report.

From your logs, it appears to be doing what it is supposed to do. For a little over 2 bills, it is a great value!

Last edited by John H.; 03-22-2019 at 10:40 PM.. Reason: Added info.
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      03-22-2019, 09:29 PM   #3
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Thank you!
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      03-22-2019, 10:28 PM   #4
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Great write up. Next on my mod list now. Does the butt dyno tell any difference?
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      03-22-2019, 10:35 PM   #5
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Originally Posted by top ramen View Post
Great write up. Next on my mod list now. Does the butt dyno tell any difference?
Well now that Im FBO Next on the mod list will be BootMod3 and probably Meth. But this is the wifes car that Im playing with for now that will hold me over till I order and take delivery of my new toy next year. Lol

Butt dyno notices the cars performance staying strong and not falling on its face after going through the gears past 4th when the turbo usually starts to get to hot and the car starts pulling timing once iats get past 115 degrees.
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      03-23-2019, 03:25 AM   #6
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Thanks!

Were you able to put the under cover of the intercooler back on? Or the G-Plus intercooler is just hanging by the two L-brackets with nothing underneath?
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      03-23-2019, 08:29 AM   #7
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Quote:
Originally Posted by Duckysaurus View Post
Thanks!

Were you able to put the under cover of the intercooler back on? Or the G-Plus intercooler is just hanging by the two L-brackets with nothing underneath?
No I wasnt the new one hangs to low and with the brackets it wont fit.
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      03-25-2019, 10:27 AM   #8
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Thanks for taking the time on the write-up! IAT's prove that this is a solid budget option.

I would suggest finding a way to reinstall the undercover back on. This in theory will help stay cool. Undertrays create a suction of air for the cooling items as it blocks air from leaving the correct path. With the tray installed there is only one way for air to travel. Would you be able to install some spacers and use longer undertray screws?
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      03-25-2019, 10:37 AM   #9
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Originally Posted by trialmountain View Post
Thanks for taking the time on the write-up! IAT's prove that this is a solid budget option.

I would suggest finding a way to reinstall the undercover back on. This in theory will help stay cool. Undertrays create a suction of air for the cooling items as it blocks air from leaving the correct path. With the tray installed there is only one way for air to travel. Would you be able to install some spacers and use longer undertray screws?
Thanks! So there were two trays, one that was apart of the under body and a second one that was the actual support and mount for the stock intercooler. I put the one tray that was apart to the under body back on so the air will not redirect under the car with this installed.

This is the one I put back on...
Attached Images
  
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      03-25-2019, 10:56 AM   #10
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Awesome, glad that one still fits!
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      03-25-2019, 11:15 PM   #11
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So if the one that was the support and mount for the stock IC was removed, the only thing really securing the G-Plus IC are the two L-brackets and the hose mounts, correct?

Do you feel that they're stable/strong enough to handle potholes as well (I live in NYC).
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      03-26-2019, 12:48 AM   #12
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Quote:
Originally Posted by Duckysaurus View Post
So if the one that was the support and mount for the stock IC was removed, the only thing really securing the G-Plus IC are the two L-brackets and the hose mounts, correct?

Do you feel that they're stable/strong enough to handle potholes as well (I live in NYC).
Yes the 2 L brackets and hoses are the only things holding the intercooler but that is plenty. It is very secure and since its such a tight fit I dont think it will be able to come loose easily anyways.
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      04-13-2019, 09:51 PM   #13
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How is this performing so far? Really interested in purchasing one but would like to hear a review on it.
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      04-13-2019, 09:53 PM   #14
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Quote:
Originally Posted by Alimon777 View Post
How is this performing so far? Really interested in purchasing one but would like to hear a review on it.
So far so good! Havent done any recent tuning pulls but might do one just to see how everything is looking as the weather gets hotter here in Az.
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      04-14-2019, 01:40 AM   #15
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Quote:
Originally Posted by Bullitts5 View Post
Quote:
Originally Posted by Alimon777 View Post
How is this performing so far? Really interested in purchasing one but would like to hear a review on it.
So far so good! Havent done any recent tuning pulls but might do one just to see how everything is looking as the weather gets hotter here in Az.
Does this add hp at all ?
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      04-14-2019, 08:33 PM   #16
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Very nice, I'll be doing this soon, very helpful information. Thanks!
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      04-16-2019, 11:37 PM   #17
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Quote:
Originally Posted by jonobro View Post
Quote:
Originally Posted by Bullitts5 View Post
Quote:
Originally Posted by Alimon777 View Post
How is this performing so far? Really interested in purchasing one but would like to hear a review on it.
So far so good! Havent done any recent tuning pulls but might do one just to see how everything is looking as the weather gets hotter here in Az.
Does this add hp at all ?
Not actual HP but does improve the performance of your vehicle in the aspect that when your IATs are lower the vehicle is able to perform at its very best. When are cars start to see IATs over 115 they start to pull time therefore decreasing the performance of the car.
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      04-18-2019, 03:51 AM   #18
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Do they make this for a 2011 335i n55
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      04-18-2019, 11:59 PM   #19
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Do they make this for a 2011 335i n55
Im not sure take a look on ebay
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      04-19-2019, 07:39 AM   #20
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Gr8 job thanks for taking time to post
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      04-20-2019, 06:44 AM   #21
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Quote:
Originally Posted by Duckysaurus View Post
So if the one that was the support and mount for the stock IC was removed, the only thing really securing the G-Plus IC are the two L-brackets and the hose mounts, correct?

Do you feel that they're stable/strong enough to handle potholes as well (I live in NYC).
This is exactly how Wagner Interncooler is fitted as well. I have Wagner Intercooler. I was not able to install plastic tray that supported IC.
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      06-20-2019, 09:44 PM   #22
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Quote:
Originally Posted by Bullitts5 View Post
So last week I ordered a G Plus intercooler after my IATs started to climb to the 130s. I live in Az and I need to make sure my car stays cool during the summer. At first I was going to order a Wagner and then I heard about the VRSF Intercooler coming out and after all the back and forth Ive heard about everyone going through I just went ahead and ordered this one.

Let me start out with "Its a tight fit" is an under statement but it eventually does. Some members were asking me for some comparison pics and fin per inch pics so here are those. Ohh and my intercooler did not come with brackets so in this DIY I show you how I made mine for less than 10 dollars if you have all the tools.

[IMG]https://ibb.co/X5j32Tt[/IMG]

[IMG]https://i.postimg.cc/y8XgKtPM/IMG-1494.jpg[/IMG]


[IMG]https://i.postimg.cc/J0k5M8PN/IMG-1512.jpg[/IMG]

I started with putting my car on drive up lifts
[IMG]https://i.postimg.cc/bYs6mcHN/IMG-1498.jpg[/IMG]

Then once it was up on there I began removing the under belly pan/cover of the intercooler and radiator with an 8mm socket, 4 connected to the bumper and then 6 or so to the under belly cover.

[IMG]https://i.postimg.cc/k4DBx4mC/IMG-1499.jpg[/IMG]

[IMG]https://i.postimg.cc/XvjZYL1p/IMG-1500.jpg[/IMG]

After removing that I removed the Intercooler securing tray with a Torx bit T25. There are only two screws for that, and these are the ones you will be using with your intercooler brackets.

[IMG]https://i.postimg.cc/wjd0xtK7/IMG-1505.jpg[/IMG]

I would probably wear safety glasses during this cause there was so much dust and debris around this area dirt and bugs carcasses were constantly falling in my eyes. It was annoying.

Now go ahead and use a large flat head screw driver to unsecure the hose clips. Just pry the clip away from the hose they do not come off they stay attached but once lifted up it will loosen the clip at the sides as well.


[IMG]https://i.postimg.cc/ZKNwh8MG/IMG-1504.jpg[/IMG]


Once you've done this to both hoses, you will need to push the intercooler towards the front of the car so the tabs on the intercooler have a fee path so the intercooler can slide out.


[IMG]https://i.postimg.cc/HWc2Q0dr/IMG-1509.jpg[/IMG]


It will take some wiggling but the stock intercooler comes out pretty easily.

Now comes the hard part. Start sliding the G plus intercooler into the location you pulled the stock one from. The oil lines tend to get in the way so I would try to zip tie them up or out of the way or I was able to position them so they didn't interfere with what I was doing.

I had a hard time getting the intercooler in both sides at the same time. The driver side was the easiest. But once you get that side in don't attach the hose yet. The passenger side is very very difficult and takes some persuasion. Also make sure before you get the intercooler all the way into place you have the electric fan on the inside of holding brackets or you will be trying to pull the intercooler back down enough to get that into place.


I had a very difficult time getting my hoses attached at this point the driver side attached easily but my passenger side was a real pain in the rear. But after some persuading I was eventually able to get it attached and had the intercooler attached and in place for me to make the brackets.


[IMG]https://i.postimg.cc/PqVWDJ7b/IMG-1517.jpg[/IMG]

Now some of you may laugh but instead of using just flat bar I went this route. I purchase two 90 degree shelf holders. They are powder coated black and have a clean 90 degree bend in them already.

[IMG]https://i.postimg.cc/XNRgxZYQ/IMG-1513.jpg[/IMG]

So it just took me to drill a few holes and a small cut to bend the top of the tab so that it was parallel with the mounting surface of the car. As well as bending the 90 degree just a little out. Youll have to do a few mock up trials to figure what degree you need but mine looked something like this. I will eventually tig weld the brackets up where I cut the tab to bend it but didn't have access to my buddies welder today.


[IMG]https://i.postimg.cc/T3GJMZmb/IMG-1514.jpg[/IMG]


[IMG]https://i.postimg.cc/2SwFz2FK/IMG-1516.jpg[/IMG]

Now technically since you have to cut and drill on the piece the whole powder coated part doesn't really matter and once I weld the bracket up Ill have to clean the powder coat off so that whole part was just in hopes that it was going to be a straight 90 degree bend down to the intercooler but it was not that simple one mine. hence the cut and bend of the bracket. Even tho their brackets appear to be that way and other DIY post show that mine was not that way for some reason.


Once everything is installed and tighten all you have to do is button up everything and pray you did everything right and you have no boost leaks lol


I went and recoded some logs with the ambient air being 75 degrees and my IATs never saw over 91 degrees.


Before Log

[IMG]https://i.postimg.cc/ZnjcRH6H/Before-Log.png[/IMG]


After Log

[IMG]https://i.postimg.cc/4yXPsqHn/After-Log.png[/IMG]

Hope this helps everyone and feel free to ask me any questions you guys have.
Quick Question, I had the wagner intercooler installed today and was on stage 1 93 bootmod3. Power dropped all the way down to below 200 hp and below 200 torque. Protuning freaks told me to update to stage 2 as that tune is configured for a downpipe and the front aftermarket intercooler. Still my power is limited. Never had this problem on stage 1 with stock intercooler? Anyone have some ideas?
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