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      01-05-2019, 12:52 AM   #1
WeekendWarriorz
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F8X S55 owners BEWARE!! Charge cooler failure

Hello everyone,

I'm not around on this Section of the forum but have and still am gaining more knowledge of the S55, but am knowledgeable to the N54/N55 platform and linger on e90post/1addicts. Recently a buddy of mine with a F80 M3 has been receiving drivetrain malfunctions, down on power, and extremely hot air intake air temps, the charge air cooler as you guys know should be cool to the touch.

Car goes into diagnostic at a local performance shop and find this: (see images below). After pulling the intake manifold off the car.

Yes that's right, seems like the factory charge air cooler has leaked the cooling fluid through the core and gone directly into the intake manifold, and through the intake valves directly into the engine. From what I've seen this is the first that has happened on this platform. The car will be repaired and back running in a few days. But as a PSA seems like upgrading the stock heat exchanger to prevent a 2k+ failure/repair like this is the way to go.
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Last edited by WeekendWarriorz; 01-05-2019 at 01:42 AM..
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      01-05-2019, 01:25 AM   #2
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Good info, thank you
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      01-05-2019, 01:31 AM   #3
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Good grief, isn't there a danger of hydrolock there?

Thanks for the info.
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      01-05-2019, 01:36 AM   #4
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Quote:
Originally Posted by NickyC View Post
Good grief, isn't there a danger of hydrolock there?

Thanks for the info.
Absolutely, I'm surprised it didn't hydrolock... but after the fluid drained into the engine it either went into the oil and can cause excessive wear on rotating parts (rod bearings for example) or evaporated with the heat generated from combustion. Whichever happened though it isn't good!
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      01-05-2019, 01:51 AM   #5
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Mind sharing what kind of DTCs your friend was seeing?
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      01-05-2019, 02:07 AM   #6
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Quote:
Originally Posted by nars3000 View Post
Mind sharing what kind of DTCs your friend was seeing?
This was it if I recall correctly
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      01-05-2019, 02:34 AM   #7
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Was the car worked on before and what modifications does it have?
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      01-05-2019, 02:45 AM   #8
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Quote:
Originally Posted by Justin.AutoTalent View Post
Was the car worked on before and what modifications does it have?
The car has only seen Newport Beach BMW and Mckenna BMW for routine service since new, both reputable dealerships in SoCal. Previously had a JB4 (junk box 4) on it over a year ago with a few hundred miles before being taken off is what I'm told. Nothing that could have been correlated to the failure In my opinion.
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      01-05-2019, 12:09 PM   #9
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We have replaced two so far. Not caused by any mods. Both were internal core leaks.
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      01-05-2019, 12:25 PM   #10
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What year and mileage.
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      01-05-2019, 12:30 PM   #11
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one 15, one 16.

50k+ on first one, correct fluids and maintenance. Other was lower mileage. If you are losing fluid from the HX reservoir you know where its going if it isn't on the ground.
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      01-05-2019, 01:11 PM   #12
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This is a 2018, I believe around 15k miles.
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      01-05-2019, 01:23 PM   #13
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Mine was leaking too and I had no codes. It's best to check the IC reservoir to if its leaking or not.
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      01-05-2019, 04:30 PM   #14
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Quote:
Originally Posted by ///F80M3 View Post
Mine was leaking too and I had no codes. It's best to check the IC reservoir to if its leaking or not.
This doesn’t surprise me at all… However that is not the only place it can leak from as I found out about four months ago my charge coolant expansion tank had to be replaced because I had a slow leak although I saw no evidence or could smell anything either which was extremely odd. I just knew it was leaking internally. All is good now :-) sidenote, both my charge cooling expansion tank and engine block coolant expansion tank have been replaced one each. 2016 M4
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      01-05-2019, 05:19 PM   #15
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Quote:
Originally Posted by MDM View Post
Quote:
Originally Posted by ///F80M3 View Post
Mine was leaking too and I had no codes. It's best to check the IC reservoir to if its leaking or not.
This doesn't surprise me at all… However that is not the only place it can leak from as I found out about four months ago my charge coolant expansion tank had to be replaced because I had a slow leak although I saw no evidence or could smell anything either which was extremely odd. I just knew it was leaking internally. All is good now :-) sidenote, both my charge cooling expansion tank and engine block coolant expansion tank have been replaced one each. 2016 M4
How did you find out there was a leak? I'd like to check my car. Haven't had to add a whole lot of coolant but maybe half a cup every few thousand miles.
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      01-05-2019, 09:08 PM   #16
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So I should call CSF ASAP now.
Thank you for taking your time and sharing the information.
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      01-05-2019, 10:01 PM   #17
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Quote:
Originally Posted by M3anPower View Post
So I should call CSF ASAP now.
Thank you for taking your time and sharing the information.
Better to be safe than sorry. Seems like there's been a few of these and no one has documented this failure. A used S55 + labor for a swap doesn't sound cheap as opposed to a CSF cooler in my opinion!
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      01-05-2019, 10:16 PM   #18
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      01-06-2019, 12:52 AM   #19
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Quote:
Originally Posted by MDM View Post
This doesn’t surprise me at all… However that is not the only place it can leak from as I found out about four months ago my charge coolant expansion tank had to be replaced because I had a slow leak although I saw no evidence or could smell anything either which was extremely odd. I just knew it was leaking internally. All is good now :-) sidenote, both my charge cooling expansion tank and engine block coolant expansion tank have been replaced one each. 2016 M4
One of my buddies brand new M3 comp pack had same issue ~ 9941miles on a 2017 model. He's getting is replaced under warranty
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      01-06-2019, 09:48 AM   #20
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For us laymen, is this something we could check and if so how?
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      01-06-2019, 09:52 AM   #21
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This is common on boosted cars. You realistically should have NO fluid consumption in the intercooler.
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      01-06-2019, 01:34 PM   #22
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Quote:
Originally Posted by gatorfast View Post
For us laymen, is this something we could check and if so how?
Open up the reservoir for the charge air cooler, I would just monitor it every few weeks. If you notice fluid dropping then there would be a concern. For example: you could use a straw and then the first time you measure use a sharpie and mark the height of the fluid.
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