[lightmanek]

Hi everyone!

Short introduction: bought my 2006 BMW E92 MSport pack in 2014 with 83k miles on the clock and still under BMW extended warranty. I've took additional year of it and thank god for that as I had 2 clutches (no DMFW replaced, confirmed with mechanic), water pump, all six injectors, HPFP and gearbox replaced under warranty. Least to say I never ever before spent so much time at the dealer within 1 year with any previous car I owned! I was patient and did not tune it in that period, covered 20k miles in that year and then decided to cancel warranty and start my journey with remapping and modifications. Honestly, since I've stopped visiting BMW service here in Devon (UK) my car never broke down again (I was towed twice before)!
Now it sits at 177k miles and I had engine out and back in every year since 2015, improving, modding, fixing wrong turns, improving ... you get the pattern.



I've been running custom BQT 500HP+ map since 134k miles and various 350HP+ and 400HP+ maps prior to that.

One of the runs on work in progress map:



List of mods I remember (some I'm bound to forget as there are many):
- Hybrid Perun Turbo Stage 2 (hot and cold side enlarged)
- Exhaust manifold modified to accept EGT probes
- LPFP - Walbro 450 with custom mount
- DCI intake
- MMP 2'' Inlets
- Custom stainless steel 2'' outlet
- Aluminium charge pipe with HKS SSQV IV BOV
- 25 row eBay oil cooler kit (https://www.ebay.co.uk/itm/161730542727) mounted in place of original
- BOSCH 4BAR TMAP
- BMW 550i/335IS clutch
- Clutch delay valve delete
- Air scoops
- FORGE 7'' FMIC
- Full Aluminium sport radiator
- NGK sparks gapped to 0.22
- RM Motors 3'' catless downpipes
- Custom welded stainless exhaust with Magna Flow 3'' sport cats (300 cels) - had it with Vibrant resonators before, but a bit too noisy and risky to drive on Authoban without cats, hence brought back secondary catalytic converters
- MG Motorsport Muffler (love the sound!)
- BMS Oil Catch Can
- Telescopic steering rod from BMW 1 series diesel to gain precious space for outlet in RHD car (it's thinner where matters for routing pipe)
- MHD
- uprated break discs and pads
- 335IS Engine mounts

So as mentioned earlier, I've been running this car with more and more mods since 103k miles without any significant issues, only self inflicted ones like bad outlet mount due to RHD car which would slip and I would fix it on the side of the road to carry on my journey soon after! I've been slowly finding out best solutions to fix these issues and in the meantime covering tons of miles each year (average 20k+ per year).

Now onto my annoying issue!

I'm getting cylinder 5,6 and sometimes 4 misfire when engine is warmed up and I do WOT in 3rd or higher gear. Misfire will happen around 6000+ RPM and almost every time I do a pull (it was less frequent going back in time, but definitely was present already at 134k miles). It's not there when I load stock map. It does it on any fuel I use, from standard Euro95 to V-Power Racing 100+.
So far I've tried:
- LPFP upgraded to Walbro 450
- New fuel filter assembly with pressure sensor
- 2 new BOSCH coils, swapping them and so on
- Spark plugs changed every 20k miles, tried both BOSCH and NGK
- MHD Stage 1 to 2+ maps with various fuel targets
- Lately I've rebuild engine with refurbished head, new seals for valves and all relevant parts
- New VANOS sensors
- Resetting adaptations

I've spent a lot of time trying to find any clues on-line and the remaining suspects are:
- DMFW causing false misfire detections under load at hight revs (bear in mind it has 177k miles now, but works great for normal driving, smooth and quiet, mechanic inspecting it said it's still good, but that might not be good enough for my power levels)
- O2 sensors, even though I don't get any codes?
- Injectors, but they are Index 12 replaced at 101k miles, AFR is consistent between banks, no un-burnt fuel in cylinders, no hesitation on cold start, no idle problems
- ECU mosfets not driving enough current to coils? Unlikely as it would misfire on stock map, but only does on maps with above 10psi up at the top of RPM range

Latest data log:

https://datazap.me/u/lightmanek/mhd-...og=0&data=3-23

Any, even wild ideas will be appreciated!
Thanks in advance!

Moving forward, I'm going to put the car on the ramp again in late October. I've decided to get SMFW Twin Disc clutch to hopefully fix my misfire problems, as I'm planning on upping power output anyway, but haven't ordered it yet as I want second opinion.
My Perun Turbos did great, considering they have been pushing 22PSI on 500+ map reliably the last 40k miles (yes, 40000 miles without any issues, no play on shaft, no oil blown through), so I don't care if I blow them up hunting for 550WHP+

I would also appreciate suggestions as to next mod to take it to 700HP+ mark. Port injection, twins TD04 or single, meth, other?


Few select pics below:

Engine with reconditioned/rebuild head


Valves clean as they get


Engine with Perun Turbo Hybrid S2


6MT gearbox in the full glory (BMW claims you cannot repair this gearbox, but no one told my friend and master mechanic , gearbox had very slight oil leak on the joint since new)


Custom 2'' outlet


More pictures in the gallery:

View post on imgur.com

[lightmanek]

Seems that my car mods are not that interesting judging by my previous post, but regardless I'm posting update as it might help someone doing similar mods.

I'm now in process of upgrading:
- Clutch to Twin Disc SMFW kit capable of around 1400NM
- Hybrid TD04H turbines from TX Performance
- BL Coils from Audi R8
- upgrade to BMS Dual Cone intake with larger filters or full relocation to the turbo side (decision in the next 3 days)
- upgrade to suspension, all 4 corners Eibach B8 springs and Bilstein B12-Pro shocks
- front brake conversion to F30 discs

Apart from that, normal maintenance, 4 O2 sensors replacement and few more things.

View post on imgur.com

UPDATE 29/10/2018
Going ahead with intake relocation on RHD car - major PITA


work in progress, but already few crucial inches gained!



Small part of engine block had to go for the pipe to fit perfectly

More pics from today ...

View post on imgur.com

Will update this post as things progress ...

[threetirtyfive]

Awesome stuff major work.
Did u just reshell oem rods instead of going forged?

[mweisdorfer]

Maybe try changing your plugs to NKG 2 steps colder and gapping at .018.

Eldor coils?

I've read mixed reviews on Bosch coils on a tuned engine. I've never read negative reviews on Eldor Coils on a tuned engine.

Just my 2 cents

[hellokitty]

Originally Posted by mweisdorfer

Maybe try changing your plugs to NKG 2 steps colder and gapping at .018.

Eldor coils?

I've read mixed reviews on Bosch coils on a tuned engine. I've never read negative reviews on Eldor Coils on a tuned engine.

Just my 2 cents

This. Perhaps it would make sense to rule out ignition and do a PR coil setup with NGK 97506s at .018 gap.

[hellokitty]

Also drivetrain “noise” could cause misfire issues at high rpms. Merge boost addict together and you have the link.

https://www.boost addict.com/showthread.php?32910-stock-DMFW-misfires-on-high-HP-N54s

[mweisdorfer]

Originally Posted by hellokitty

This. Perhaps it would make sense to rule out ignition and do a PR coil setup with NGK 97506s at .018 gap.

Yep, I saw that the OP was close to 500hp. I've read that you should go 1 step colder for 100hp over stock & 2 steps colder if you are 200hp over stock.

[lightmanek]

I'm back after few months without my car ...
Long story short, VANOS on my car died soon after fitting big twins. Local mechanic in UK replaced it for me and managed to somehow contaminate engine oil with metal particles. I was mad, I was sad, but I didn't give up. Shipped my car back to the garage in Poland who did all the major work and asked them to rebuild my engine.

I will upload a lot more content over the weekend but here is short clip and few pics of work in progress:







Regarding issues with misfire, they are gone!
So either this was down to eldery DMFW, or as it turned out, slighly bent crankshaft ... it was out of balance by 0.15mm

This has been a rought journey the last few months, but the wait was woth it! The car now runs perfectly! I'm only running old BQ Map created for TD03 hybrids with 20PSI, but it's good enough for this:

Virtual Dyno is telling me 493WHP (555HP) and 513lb/ft (700Nm) and this was calibrated with proper dyno when I had a chance, so it should be within 5%. Ran on the same stretch of the road as my previous VD's to which I could calibrate numbers with the real thing.

Now I can start working on a new maps and slowly tune it to extract most out of 99RON fuel I can buy here. In the summer I will try E85 and flex-fuel.

Any questions I will be happy to answer!

[jokers_greg]

Curious what this Polish mechanic was charging!

[Yam_440i]

Please keep this thread going with updates.

Some crazy outstanding work done on this car!

[lightmanek]

Mechanic charged me 3500PLN for all the work this time around. Parts and refurbishments were 8000PLN.
This is quiet cheap as I get returning customer discount, but even without it, you would be looking at about 4500PLN for labour.

I will update this thread over the weekend as promised. Car is a beast now and pure joy to drive. Successfully outaccelerated new M5 2019 from 50MPH to 110MPH and new Porsche 911 GTS 2019 model (that was easy).
Very happy camper!

[lightmanek]

I have so many pictures and this car has a long 4 year history of modifications, but I will try to keep it to the newest and most exiting toys.

Exhaust - various stages from modified stock to full semi-custom dual 3'' stainless steel with Magnaflow Sport cats:

I went through many iterations of my exhaust, but have documented few major stages below.

- stock + downpipes, 2nd cat delete and PE mod - pretty much straight pipe exhaust













Before, I ran only with 2nd cat delete and car sounded louder than stock but reasonably tame, after PE mod and DP it became very prone to drone (2000RPM and 5500RPM were most resonant freq.) and simply too loud (for Police and driving at night in neighborhood)!

Videos below, but they don't do the justice as mic auto-leveling dampens the sound:

last video shows it best ...

- refitting 2nd cats cured most of the problems with drone but car was still quite loud when on it

- building dual 3'' exhaust with MG Motorsport street muffler






Quality welds all around! I was privileged to have a factory tour and see interiors of these babies! There is a lot of perforated piping and tubing inside the muffler

Moving on, my mechanic had to build the mid section between downpipes and muffler. It was a slow, 4 day job as each weld had to be first just tacked on, section measured, aligned, then next bit spot welded and so on. Only after major part was completed, more complete weld could be done, still watching not to overheat it and cause steel to wrap. RM Motors DP's were also modified to remove 2.25'' reduction no longer needed for our custom exhaust.






Clearance was an issue almost everywhere ... but luckily not impossible to find a way!






Tail end of business - not quite there yet!

We went with Vibrant resonators which I bought for my old stock system, hence they were 2.5''. For TD03 hybrids this was still plenty of flow, so we installed them.









Lowest part of exhaust was now below car's floor, so I was worried about hitting speed bumps with it. Turned out to be a non-issue.



Very little margin left



After enjoying my new setup for few months, I had only one complaint! Smell of fumes when in stationary traffic, especially with windows down (the only way to drive car sounding this good )
So I had to do my final (so I foolishly thought!) modification and bought these:
Magnaflow Sport cats 300 cells (stock BMW have 600 cells)






Almost perfect!
Now I was getting lovely sound, still loud but not stupidly loud and no drone. The only little complain I had was exhaust vibrations at around 2000RPM were transferred inside the cabin and would shake rear seats and trim! With passengers inside, this was a non-issue but when driving alone I was keeping my car above 2500RPM to avoid vibrations.

The solutions was another small modification:




This is my most complete and final revision - sorry for messy picture.



And this is how it looks on the car:




Video:

Both of the above were still with TD03 hybrids.
I will record and upload new video soon, this time with my newest TD04 setup! Car is slightly louder all around

Here is promised video of the exhaust sound with my newest mods:

Complete gallery:

View post on imgur.com

What should I make my next post about?
1. TD04 hybrids
2. Air intake and outlets
3. Suspension and breaks
4. Engine cooling
5. Anything else?

[x77md]

Awesome thread, do you have more pictures of the turbos themselves? Never heard of them before

[lightmanek]

Thanks x77md !

These turbos are from TX Performance (Turboexpert.pl) and exactly this model:
https://www.txperformanceturbo.pl/se...e-4-700km.html

They also have Facebook page with a lot more stuff they do. One thing to say about them is that they are well know in drift circles and their products are in many high profile cars (check FB page).

https://www.facebook.com/TXPerformanceTurbo/


Here are pictures of my new TD04H (these were early models requiring oil and water line modifications, see below)






Comparision of sizes, left TD04H, right TD03 Stage 2+



First mockup fitment on the engine block





As you can see, no space left for good pipe clearance and I didn't want to have a kink in air intake.






Nothing an angle grinder can't fix




Now onto custom made water and oil lanes ...







Finally I needed some solid (pun intended) outlet I would no longer have to re-do again.




and custom inlets (dual 83mm pipe)



Pay attention to the steering rod ...



This was stock on my car



but was eating precious space where there was none! Swapped for BMW 120D telescopic steering rod to gain few milimiters



Finally a bit of black paint and some padding here and there to minimise metal on metal rubbing.




Remeber my 2nd post from this thread showing a bit of cutting inside engine bay? This hopefully give anyone thinking of air intake relocation for big twins
on RHD car a bit of an idea as to how crammed this whole space is and that there is no chance to fit 2''+ inlets, turbos and steering rod there without squeezing something.
We went a bit crazy with modifying main frame leg, but my mechanic build frames and engines for rally cars, so I was in good hands.

Hope someone will find this post helpful!


Sorry for bad camera operator, this was his first time taking turn a bit sideways!

Sound of my current setup from inside of the cabin:

and just after cold start:

Finally, for anyone interested, my VD at 20PSI target on VPower 99 (UK's best widely available fuel). Map is an old version tuned for my TD03 Hybrids, I finally have received new map for TD04's, but have to log it and make sure we are not overdoing things, so stay tuned for more results soon!



Blue line was my stock car before wallnut intake cleaning. That was in 2016!

[mike@x-ph.com]

Thank you for sharing

[lightmanek]

Small update - installed N20 TMap sensor as per my tuner request and tried first iteration of map for my new turbos.

I did few pulls and all seems fine, but two were on a fairly flat bit of tarmac:



Green - stock map with stock turbo and DCI intake (baseline)
Red - Hybrid TD03, FBO+ (previous best map from BQT targetting 20PSI)
Blue - current setup with TD04H hybrids (new map targetting 22PSI at the top)

This had some corrections as I just switched from Tesco Momentum 99 to Shell VPower 99. Still I was very happy with how car pulled and engine reacted to the load.

Then my final pull was on a bit of road I did all my previous pulls and it felt fantastic, but I started it a bit too early and there was a small bump in the road. You can see it at around 4300RPM, car bounced twice and then shoot off!

This seems too good to be true and probably is. I will have to book dyno, but first I will wait for BQ to get back to me with his assesment and potentially another revision of this map.

Anyway, take it with a grain of salt, but believe me, after inital bump and slip, there was no more traction issues, so the latter part of VD graph should be direcly comparable to my older logs done at the same spot. Massive improvement



Oh, and for those who can't remember beginning of this thread, I'm running twin disc clutch with SMFW so it's not clutch slippage

https://datazap.me/u/lightmanek/bmw-...og=0&data=3-22

[Chappers 71]

Impressive stuff,

[lightmanek]

I'm back with a short update.
Today I had time to take my car to a local dyno and finally get some representative numbers!





Ready for the pull ...

Video didn't start from the begining because someone had to call me at this exact moment :mad:


Ignore AFR and lambda readings, they were not done as I've logged this run with MHD.
https://datazap.me/u/lightmanek/dyno...1-22-27&solo=3

I was positively surprised, but the guy doing dyno was shocked!
Straight Shell VPower 99, but please remember, this is crank HP and not WHP!
I think there was a bit left there as IAT was high and this shop had only small fans blowing on the car, so run started at 40C and second run was at 50C producing 689HP, 3rd run 692HP and the last one was 689HP. All runs done within 10 minutes, so no cooldowns between them.

I am very happy with this result, but as you can expect, I'm already planning my next step in a quest to higher power!
This map is too demanding on my HPFP, so I have to do something about that and make no mistake, this map is not for daily use. BQ alrady lowered boost by 1PSI and changed VANOS strategy with the newer iteration, which should be safer for daily use.

I will enjoy my car as it is for two months and then push it further!

[buddyboy]

Great thread, just finished reading it. Did you say you upgrades the brakes with F30 calipers, i didnt see any pics in the thread

[lightmanek]

Originally Posted by buddyboy

Great thread, just finished reading it. Did you say you upgrades the brakes with F30 calipers, i didnt see any pics in the thread

Thanks!

I've upgraded with F30 discs as I was warping single cast discs no matter which manufactured (Black Diamond, EDC, OEM).
I must say, so far so good! I've done just over 5000 miles on them where even cut and drilled BlackDiamonds were already wrapped after 3000 miles and unbearable after 10000 miles.

Here are few pics:





Hope this helps!

[buddyboy]

Originally Posted by lightmanek

Thanks!

I've upgraded with F30 discs as I was warping single cast discs no matter which manufactured (Black Diamond, EDC, OEM).
I must say, so far so good! I've done just over 5000 miles on them where even cut and drilled BlackDiamonds were already wrapped after 3000 miles and unbearable after 10000 miles.

Here are few pics:



Hope this helps!

\\Thanks for the pics, so you are using 370mm F30 discs with your e92 calipers? To me it looks like there is not much pad contact with the disc. Surely that will wear a massive groove in the disc? Have you thought about the f30 calipers?

[Luke335i]

I’m very new to this site, I have a 09 335i us spec car. I’m thinking about upgrading to the pure stage 2 turbos, I’m just wondering what else are some good upgrades to go with it? Will my jb4 g5 work with everything properly or do I need to do anything else? Will stock fueling be an issue ? I just need some advice on the best options to upgrade my car. Seeing you all have be there & done it. I would love some advice on products and parts to replace & change.