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BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Powertrain and Drivetrain Discussions > N54 Turbo Engine / Drivetrain / Exhaust Modifications - 335i > Early birds, early pictures. n54 rebuilt.



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      07-06-2013, 04:41 PM   #1
CSL335i
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Early birds, early pictures. n54 rebuilt.

Let me introduce myself. My name is Laszlo and I am located at Budapest/Hungary/Europe. I am a proud owner of different BMWs, such e93 M3, F10 M5, F20 125d, e92 335i. At this moment i would like to introduce some early pictures about my e92 335i DCT rebuilt, which has started almost a year ago. And we still need some time to finish, hopefully by the end of this year.

Regarding my e92 335i, all rebuilt has begin, when i was on a business trip with my 335i and my secondary oil cooler line has wear and blown up.
I have lost 4.5 liter (!!!) oil from 6.5Liter. Oil line was replace, engine was refilled with oil and however i cannot hear any damage or strange noise, i decided to tear down the engine, check everything and completly rebuilt. NOt just the engine, of course. During my project, the following topics were involved. I have tons of pictures, some topics are finished or almost finished, some needs to be finalized.
All of the modification is done in-house by my tech-friends.

My car is/will be street driven, sometimes, spirited, sometimes hard.

THIS PROJECT IS NOT ABOUT HUGE HPs, BUT ABOUT THE PATH WHICH I AM WALKING ON AND RESULTS SOME INCREDIBLE MOMENTS AND TECHNICAL INNOVATIONS.

1, Interior.
Custom leather upholstery, Recaro Sportster CS seats with seat heating,
additional display for engine datas, Turbo RPM display x 2, EGT display

2, Full M3 suspension conversation.
Front: LEFT and RIGHT tension strut WITH RUBBER MOUNTING, LEFT and RIGHT wishbones, LEFT RIDE HEIGHT SENSOR BRACKET, REGULATING RODs, M3 Bilstein B6 coilovers, M3 FRONT coil springs, LEFT and RIGHT wheel carrier,
Guide support and spring pad. H&R sway-bar.

REAR: REAR AXLE CARRIER, LEFT and RIGHT RUBBER MOUNTINGs, LEFT and RIGHT wheel carrier, Rubber mountings, LEFT and RIGHT camber links, LEFT and RIGHT wishbone, Steering arm with ball joint, M3 Bilstein coilovers, M3 springs. H&R sway-bar.

3, Custom made Brembo brake systems.
Front: 8-pot Brembo, Two-piece floating brake disc. 380x34mm
Rear: 6-pot Brembo, Two-piece floating brake disc. 355x30mm

Properly sized and modifed F10 M5 master brake cylinder which replaces the factory one to have normal brake pedal feel and brake force for the front and rear brakes. This was custom made to my brake system.

Hand-brake is replaced by hydraulic cylinders, which actuates the rear brembo brakes.

4, Differential, half-shafts.
335i differential house with custom fitted e34 M5 differential internal.
Custom fitted 2.56 final gear (i have DualClucthTranny)
Custom fitted e92 M3 drive flanges.
Custom made transmission/differential cover.
LEFT and RIGHT e92 M3 output/half-shafts.
Motul 75W140 differential oil.

5, Custom made exhaust systems.
Ceramic coated downpipes.
Ceramic coated mid-section with HJS sport cats, etc.

6, Engine rebuilt.
JE forged pistons with ceramic coating.
Carillo forged rods.
Nitrited crankshaft and crankcases.
ReBored and rehoned cylinders.
Chocked cylinders.
Ported cylinder heads. Ceramic coated ports.
Ceramic coated cylinder heads and valves.
Slightly modified valves.
Okada plasma coils. Okada Plasma Ground.
NGK spark plag
Relocated coolant reservior.
Relocated water pump.
Custom made alu intercooler
Custom made full alu watercooler radiator
Custom fitted SETRAB oil cooler.
850W FAN with relays.
Custom made charge pipes, water lines and oil lines.
Custom made air intake system with K&N filter.
Modified BMS OCC.
Forge DV.
JB4 G5 and flash.
Motul 300W Power 5W40 motor oil.


7, Exhaust manifolds and turbos.
Custom made exhaust manifolds (will be ceramic coated)
Custom made two single-scroll hybrid turbos with BALL-BEARING CHRAs.
Turbine houses will be ceramic coated as well.
Turbos have "Twin-scroll" effect, which means:
- Both of the turbos have the same turbine and compressor wheels
- Both of the turbos have the same Compressor house.
- One of the turbo has larger turbine house, while the other has smaller turbine house (compared to each other).
- The larger turbine house has smaller wastegate, while the smaller turbine house has larger wastgate (compared to each other).
- Wastgates will be controlled by Forge actuators operated by vacuum. There is also a plan to exchange the vacuum actuators with pressure based actuators.
Theoretically, this two single-turbo all-together can produce maximum 530-550HP, not more, which is more than enough for me.

7, Full M3 body conversation
We have all of the parts, this will be the last part of the project.
After fittment, respraying will be done.

8, Wheels
Breyton 19inch
Continental SportContact P5 tyres (same as on M3)

9, DualClucthTranny
Big question is, that should i upgrade them or not. My F10 M5 has the same clucth-plates as e92 335i, so maybe the clucthes are not the weakest points.
I also purchased the 16 clutch-pack SSP clutch, but i dont want to install them until further experiences based on other forum members.

10, Fuel system upgrade
Big question also. I am intend to have 450-500HP maxium and i will not use e85. Do you think that based on my power leves i do not need to upgrade my whole fuel system?


Pictures will be posted in different posts.

Laszlo
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      07-06-2013, 04:50 PM   #2
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looks like a serious build,

as for the fuel system, if your looking at 450-500hp, i dont think a major modification is needed
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      07-06-2013, 04:54 PM   #3
CSL335i
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1, Interior

Custom made leather upholstery. Originally my car has baige interior, so i kept some of the baige moment.s
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      07-06-2013, 04:58 PM   #4
CSL335i
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3, Custom made Brembo brake systems.

We had some brembo parts in the garage, so I choosed to re-use them instead of ordering a Brembo BB kit.
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      07-06-2013, 05:02 PM   #5
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You can get in the 500 whp range on stock fueling with hybrid turbos and lots of meth. This looks like an awesome build.
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      07-06-2013, 05:04 PM   #6
CSL335i
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4, Differential, half-shafts.

These are the pictures what i made a few days ago. The M3 half-shaft already fitted to the 335i differential. The e34 M4 diff internal needed some replacement parts as well to be new.
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      07-06-2013, 05:16 PM   #7
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Just awesome keep it coming :-)
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      07-06-2013, 05:17 PM   #8
CSL335i
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6, Engine rebuilt

Maybe the more interesting part of my project together with the turbos.
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      07-06-2013, 05:18 PM   #9
CSL335i
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6, Engine rebuilt

More pictures
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      07-06-2013, 05:29 PM   #10
CSL335i
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7, Exhaust manifolds and turbos.

Part nr. 1.
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      07-06-2013, 05:30 PM   #11
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Interesting! Subscribed.
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      07-06-2013, 05:32 PM   #12
CSL335i
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7, Exhaust manifolds and turbos.

Part nr. 2.
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      07-06-2013, 05:34 PM   #13
CSL335i
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7, Exhaust manifolds and turbos.

Part nr. 3.
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      07-06-2013, 05:36 PM   #14
CSL335i
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Water cooler radiator

Need some modification as well.
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      07-06-2013, 05:37 PM   #15
CSL335i
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Custom made intercooler...

made by one of my friends.
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      07-06-2013, 05:39 PM   #16
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Wow!!!
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      07-06-2013, 05:40 PM   #17
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Very cool
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      07-06-2013, 06:01 PM   #18
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you will keep the CR the same or lower?
i think the DCT can't handle the torque from the new turbos and ported heads

good luck..
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      07-06-2013, 06:19 PM   #19
CSL335i
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Quote:
Originally Posted by 135iDCT View Post
you will keep the CR the same or lower?
i think the DCT can't handle the torque from the new turbos and ported heads

good luck..
CR 10.0:1
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      07-06-2013, 06:51 PM   #20
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Quote:
Originally Posted by CSL335i View Post
made by one of my friends.
whoa, those are some CLEAN welds. He does good work!
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      07-06-2013, 07:07 PM   #21
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Looks like a very cool build! Couple questions. All this work for 530-550WHP? The stock motor can handle that and last for thousands of miles, any reason you build it to run that power level? The orientation of your turbos, the rear intake is going to be inch or so from the front DP. BMW ran them opposed for a reason to keep all the keep in the middle away from the compressor housings. Any intake piping you run there is going to get very hot no matter how much heat shielding you run on it. Well thats about the only questions I have. Looks like a pretty serious project. Nice job!
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      07-06-2013, 08:45 PM   #22
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Quote:
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whoa, those are some CLEAN welds. He does good work!
+1 Those are nice looking
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