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.
I have already opened a new thread on the other forum, but would like to open here as well.
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.
Interior.
Custom leather upholstery, Recaro Sportster CS seats with seat heating,
additional display for engine datas, Turbo RPM display x 2, EGT display
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.
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.
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.
Custom made exhaust systems.
Ceramic coated downpipes.
Ceramic coated mid-section with HJS sport cats, etc.
We finished the end-section and will continue the exhaust system,
once we are ready with the exhaust manifolds and downipes.
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.
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.
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.
Wheels
Breyton 19inch or OEM BBS 19inch, not decided yet.
Continental SportContact P5 tyres (same as on M3)
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.
Fuel-System upgarde
Big question also, that should i upgrade them if i will have no more 500HP?
I will post pictures as well regarding the topics soon.
Happy visiting! Laszlo
4 Attachment(s)
Full M3 suspension conversation.
We install every bits of M3 supsension including the following:
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.
15 Attachment(s)
Custom made Brembo brake systems.
We have some Brembo stuff in the garage, so I choosed not to order BBK, but install what we have.
Front: 380x34mm two peace brake discs (D2 Raceing discs). Brake hat was custom made by us. 8-pot Brembo brake caliper (I think they came from an RS5).
Rear: 355x30mm two peace brake discs (Brembo discs). Brake hat was custom made by us. 6-pot Brembo brake caliper.
Master brake cylinder: to improve the brake pedal fee based on my 8 and 6 pot huge Brembo brake calipers, we decided to measure the factory brakes/fatcory master brake cylinder and upgraded brakes. We made some calculation how we should increase the capacity of the master brake cylinder
to have the same pedal fee, while have the same brake force % for the front and rear (based on my custom setup).
Conclusion: F10 M5 master brake cylinder has the same capacity, what we needed, so we took one and slightly modified it to fit the 335i environment.
4 Attachment(s)
Differential, half-shafts.
As we have the full M3 suspension on my car, i decided to have M3 half-shafts as well. We decided to keep the 335i diff house, but have LSD in it, which is compatible with M3 half-shafts.
We renewed and custom fitted an e34 M5 diff internal with my final gear 2.56 (I have dualclucthtranny) and then custom fitted the M3 drive flanges (cannot see on the attached pictures yet, but will post pictures). We already fitted the M3 half shafts without any modification (cannot see on the attached pictures yet, but will post pictures).
Custom made differential cover is on the way, once we ready with it, i will post a picture as well.
Custom made exhaust systems
Not much pictures at this time. We have finished the end section and planned what we have in the mid-section. I put two HJS 200 cell sport cats at the begining of the mid-section.
As we did in the past, we apply ceramic coating on the downpipes (externally, internally), mid-section, end-section.
8 Attachment(s)
Exhaust manifolds and turbos.
We designed two-single scroll turbo, but with different AR turbine housing.
Ball-bearing CHRAs.
Compared to each other, one turbine house is larger, one is smaller.
The smaller turbine house has larger wastgate and the larger turbine house has smaller wastgate. And will have almost identical backpressure after the turbine side. We call it "Twin-scroll effect".
Our exhaust manifold and turbine house will be ceramic coated as well.
Wastgates at this moment will be controlled by Forge actuators, which will be operated by vacuum, however, we have a plan later to try boost operated actuators as well.
Turbos will have Turbo RPM sensors as well.
We have to design the location of the cooler pipes/charge pipes and suction pipes very carefully and definitly we will use some ceramic coating and bandage as well on different pipes to prevent overheat from the downpipes and turbine house.
