Author Topic: My turbo conversion (Read 10870 times)

Gunni · « **on:** January 02, 2007, 06:21:32 AM »

Ok here is the list of what needs to be done to convert a NA engine to turbo.
I will check everything as it gets done and provide info on what was done to do so.

Fuel and ignition :
Control over fuel and ignition : XMS Standalone done Ready for boost
Adequit injectors : 42lbs done Not installed yet-
Ignition : modding to COP to remove wires and keep things clean -
MAP sensor : Zeitronix 3.5bar absolute - done
EGT sensor : Zeitronix EGT sensor -
Wideband sensor : Zt2 kit from Zeitronix done with LCD not done -
Fuel pump : we�ll see if I need one, if so it�ll probably be a walbro unit
Rest is M42 stock injection system parts,

Turbo oiling :
Pressure line to turbo :
Oil pan dump line :
Oil Pressure for turbo : probably from the pressure sensor
Oil pan return inlet : will be welded on
Should also get Oil pressure gauge in the cockpit
And oil temp sensor mounted in oil pan as well and gauge in the car

Turbo kit
Manifold : ss ebay unit, cut and fixed, top mounted by modding the flange.
Turbo bracing : might be from where the AC bracket bolts on to the block
Downpipe and exhaust : custom made
Turbo : T3/T4 from ss autochrome kit for E36
Intercooler : from same kit "24x12x3 dimensions
Plumping : plumbing kits from ebay, "2.5 size
Turbo intake : ebay plumbing kit "3 size, my "3 air filter,
Blow off valve : same kit
Engine :
Lower compression : MLS .140 gasket
Head bolts : ARP or similar
Rest is stock.
Motor mount bushings : M20 poly motor mounts from IE done

Drivertrain :
Clutch and pressure plate : bmpd 325i clutch with Sachs 618 pressure plate
Flywheel : M20 ligthtened done

I can�t think of anything more as of now, but I�ve been thinking about this alot and these are the choices I made depending on cost and effective usage, and since this engine only cost me a few $$ and I have already used it alot in another car, I�m doing this purely for the fun of it and of course the power level,

Expected power :
10-15psi should give something like 190-230rwhp.

Altough after looking at some T4 compressor maps , and if I�m using the turbocalc excel sheet right, I�m not seeing any boost until at 5k,
unless it�s a T04B S-3 compressor but then it wouldn�t be very well suited for a 3.2 M3 engine,
I might thus just take the manifold and get a turbo locally more better suited,
but I actually need the intercooler so I might take the kit and sell the turbo locally

anyway. more as things develop,
I�m open for oppinions and suggestions

rob_e30 · « **Reply #1 on:** January 05, 2007, 09:08:42 AM »

I think you right about a T4 being too big. You might look at something like a GT3071. If you're going with the stock displacement you might want a GT2860.

I also think you'll have trouble getting the oil return into the pan. There is no depth on the upper pan on the exhaust side and there is little room to weld a bung on the lower pan due to the fins between each oil pan bolt. You could grind one off, but you still have 2 challenges... You may be at or below the oil level in the pan, causing a potential problem with drainage and you'll be returning very hot oil right back to the pickup. I've opted for a 1/2" NPT bung straight into the block. You might choose to have a aluminum pipe welded to the upper pan that comes out at a slight incline to help drainage. That would allow the oil to run the length of the pan to cool and aerate.

Gunni · « **Reply #2 on:** January 05, 2007, 11:27:27 AM »

Yea I might just go into the block, it�s probable the easiest way
I�ll get using a T28 if things go my way, maxes at 320hp so that should be perfect for this motor as I surtenly don�t entertain of reaching close to that.

bar73k · « **Reply #3 on:** January 09, 2007, 04:59:44 AM »

for your oil return line id tap it into the block like in the pic below.
i have had it like that for a while now, it was very easy to do and i have not had any problems with it.

rob_e30 · « **Reply #4 on:** January 09, 2007, 10:47:20 AM »

My machinest and I selected a similar spot, but once cylinder farther back. I didn't want to be under the motor mount and it looks like it's close enough to the block to that it won't intefer with the down pipe or WG exhaust.

nickmpower · « **Reply #5 on:** January 09, 2007, 12:03:20 PM »

damn i wish i would have gone turbo

kowalski · « **Reply #6 on:** January 09, 2007, 01:56:19 PM »

why didn't you?

Gunni · « **Reply #7 on:** January 09, 2007, 06:34:09 PM »

A kid local to me (my head work mech) bought a e36 turbo kit of ebay,
and I checked it out tonight

Conclusion .
the turbine on it suits the M42 perfectly, but the compressor is a whopping 56mm inducer, A/R .60 on the compressor as well so it�s kinda big,
but I�m going to do it anyway, and worst case senario I�ll swap the compressor for a T3 one,
I�ll be ordering the E36 whole kit very soon

It�s quite good for the price actually

Turbo
manifold
adjustable fmu with pressure gauge
bov
oil lines
hoseclamps
hoses
intercooler
gaskets and various other stuff

even if one component is bad the price is still good.

e9nine · « **Reply #8 on:** January 09, 2007, 08:07:37 PM »

Can't wait to see what you're gonna end up with Gunni

scottiesharpe · « **Reply #9 on:** January 09, 2007, 08:22:35 PM »

This is a cool project. Keep those pics a comin' !

Oh you forgot one item on your list:

--> Repaint hood after turbo cooks all the paint off it!

:-)

Gunni · « **Reply #10 on:** January 10, 2007, 03:22:01 AM »

Well I did think about having it bottom mount like the manifold suggests,
I�ll have to try mounting it ,
I also don�t think I�ll have any problems with cooking the paint

if those 900hp guys don�t with there S38 bi turbos, a M42 turbo surely wouldn�t

Gunni · « **Reply #11 on:** February 08, 2007, 06:12:20 AM »

Injectors are almost here, when they arrive I�ll be rewiring the setup for sequental injection and also retuning the xms fuel map,
the reason :
The xms is setup now to only see vacuum in the MAP compensation,
so I will open that up to the 3.5bar absolute the sensor is designed for,
That way I will have adjusted the fuel range correctly already when the engine starts to see positive pressure, and I�ll have the map tuned as well as I can.

Timing only needs to be adjusted slightly with the new pressure setup

updates as they happen

Gunni · « **Reply #12 on:** February 17, 2007, 02:37:47 PM »

Just recalibrated the MAP compensation map, it now recognizes 2.5bar boost.
not that I�ll need it.

Also the map ramp is now alot better for driving as the multiplication only goes from 0.00-1.99times , and the scale is 0-3.5bar, and with that change the ramp of fuel changes vs. map is alot better, I was always leaning out in the same cell by only giving it slight throttle and the pressure was rising to other map cells and the AFR�s went into 19-21:1, I also blaim my self for not tuning the gradient well enough but now it�s great,
now it seem to sit happily from 14:16 or there abouts.

I�ll install the injectors when I get the MLS gasket change.

Hopefully up next is the COP conversion
I also did some gtech runs and the car is great.

I advanced the timing on it and the power dropped to about 105hp
and less torque, so I guess I�m at maximum best timing, I should probably be able to drop the advance a little without loosing power, I�ll check that out sometime when I get some free time,
The AFR�s where 12.9-13.2 during those runs,

Gunni · « **Reply #13 on:** March 26, 2007, 01:30:56 PM »

Update :

Plans as always do change.
I have secured a turbo manifold, it�s a unequal lenght runners with a split turbine housing,
Perfect for the turbo I�ve not desited on using,
A Holset HX35,
Should give 260rwhp at 1bar boost or so.

When more developes I�ll update

Gunni · « **Reply #14 on:** April 17, 2007, 07:19:53 AM »

Sorry guys,
this has been cancelled.
Engine developed a rod failure and will not be repaired.