Project E36 Compact: Time for boost!

[Bluebimma]

So, I finished my OBD1 M52 build on my 1998 318ti and it just wasn't enough for me. The engine and trans feel amazing but I think its time for something else, as adding boost just seems a bit too expensive especially after building my 2.8.

Starting looking at swaps locally and almost pulled the trigger on another v8 project when I came across a full drop out from a Turbo coupe. Ive always wanted boost and to keep the weight down, since the ti isn't optimized from the factory for 50/50. The i6 vs my ls, the ls handles more neutral and has less understeer and both cars sit on the same exact suspensions. The 2.3 is, unfortunately, all iron, but most will sit behind the strut towers like the m44. The full drop out was taken from a smashed, 50k car. The guy I bought it from was a huge ford guy and took EVERYTHING for the swap.

2.3 Turbo 4 cyl. 190hp/240tq out the box with the IHI turbo






Naturally, I used a ti to go pick up the drivetrain






Got it home and just threw it on the stand for the time being.






T5 vs T56 clutch assembly


T5 clean up






Picked up a new starter, mine worked but was fugly.



Entire car harness and ecu



Fluids and filter


Started ordering parts;

Front mount intercooler kit
T3 flange to vband 3"
3" downpipe
Ford EFI to AN fittings
Aeromotive Adjustable fuel pressure regulator
Flex pipes
Full gasket kit
All Cooling pipes replaced
All vacuum lines replaced
Manual Boost controller
65mm 5.0 throttle body
2010 Mustang shift knob
AEM wideband 4110 kit
Boost gauge
Oil pressure gauge
T5 hydraulic slave
Roll pin to AN fitting
BMW SS clutch line
T5 driveshaft for conversion
E46 m3 engine mounts

Much much more to come.

[CompactHPDE]

Subscribed! Gotta love the Compacts...

[M5Hunter]

I almost went for this swap in my first e36, seems like such a cool idea!

[Bluebimma]

Yea, parts are crazy cheap! The engines are starting to dry up though so I'm looking for spares. Apparently 300hp is conservative on these engines which is great for a dd

[cooler breeze]

love the "pick up" mod with the engine stuffed in the trunk lol!!

[Bluebimma]

A lot of things have been pouring into my porch as of late, now just missing my recirculating BOV and aeromotive FPR gauge.

Found a nice an-roll pin fitting for 15$ at nook and tranny, over the 60$ at summit for a McLeod. Also, picked up a t3 .60/.63 turbo locally for 30$. JTR now makes their pinion yoke flanges from billet, news to me. Fack, I still need a new pilot bearing.

[unnatrl]

I've always wanted to do this swap! Looking nice so far. It's taking way too long though ;-)

[Bluebimma]

You have no idea how bad its killing me, im ready for the boost addiction. I did, however, cheap out on some of the smaller bits and pieces but managed to get pretty much every valve, vacuum port thingy, and whistler I could find. Hopefully itll set me up to make reliable stock or above stock power until I learn the ropes.

[unnatrl]

That's a lot of parts sitting there begging for a home!

[1ofakind71]

Damn, you weren't kidding when you said you had alot of parts sitting around!

[Bluebimma]

yea, I told ya!

Need:

Boost guage
2.5"-3" vband for the downpipe
pilot bearing
engine conversion mount
transmission conversion mount
intercooler mount
upper and lower radiator hose
heim joints for accessories
AN hose and fitting for bmw ps and reservoir. I think im going to set it up like I have the ls, using the factory bmw trans cooler for p/s
standalone wire harness relay and fuse block

[therealpbgamer]

subd for sure!

[Bluebimma]

The first engine was toast on the inside, extra well done. Picked up another from a theft recovery.


Installed the roll pin fitting in the slave.



New ujoints, JTR rear flange, Mustang 5.0 driveshaft


Painted some stuff.



Aeromotive FPR installed. Removed the prefeed dampener in exchange for fuel line press on fittings. The SVO and thunderbird rails are completely different.



Turbo rear adapter plate needs ported and polished before using. The stock looks like itd work, but that's just about it, decided to upgrade to vband to make it easier on install and cleaner look. Also moving from the E3 to E6 manifold. Using the garrett instead of the IHI as well.



Checking out some intercooler routing.



Also removing the 75 amp alternator for a 140amp alternator, hence it looking "dead" in the pics. The lsti moves 45amps while idling, two fans, and the lights going.

[Bluebimma]

The T3 garret .63/60. Ordered a 200amp alternator, a bit bigger than the stock one. Contemplating reselling it for the big block 150amp I just installed in the ls. I think I can get it in there a bit more compact with the GM alternator. Sanded the surface rust off the oil pan, then sealed it with bed liner, two coats of black metallic, and a thick coat of clear.







Got my driveshaft and valve cover back from being sandblasted today.




My new big bore throttle body came in as well. Its from a supercoupe which uses a much larger butterfly and opens up to 2.5 instead of 2". Its nearly bolt on. Requires port matching the intake and elongating two of the four holes to bolt it on.




Picked up a recirculating BOV from my friends EVO.

[Bluebimma]

Painted the valve cover and accessory bracket

- - - Updated - - -

Painted the valve cover and accessory bracket





Ported my exhaust Manifold








More Paint




Trap door and scraper kit installed








Had to change the rear main for the 1 piece oil pan design.



New Ford p/s pump




Hooray for AN fittings



Mock up











3" Mock up



Its been sitting too long, pulled the head and replaced the bolts.

[1ofakind71]

Wow, nice job!

[96bmftw]

This is definitely a unique project and I like it! You have some serious skill.

[Bluebimma]

[Bluebimma]

Progress. Not sure if I like the oil feed to the turbo....doesn't look professional to me.

[Bluebimma]

New gauges



More parts. 3" Mandrel, Heater hose, Turbo blanket, header wrap, power steering reservoir, -an10 line and fitting

[Bluebimma]

Bought some new tools for work and ended up bringing them home. Tapped all the holes on the head and block.

Went to the junkyard and picked up a throttle and cruise linkage from an old lx mustang and explorer. Also picked up some brackets to kept adapt to the 3.8 throttle body.

Found a remanned alternator from a 3.8l mustang for 13$, works perfect and 130amps.

Found an accessory bracket on a lincoln, adapts the 3.8 alternator to the 3.8 nicely.

Fit the bmw oil cylcone thing for pcv.

Making an adapter plenum for the oil feed to the turbo that will also feed the bmw oil pressure sensor, the oil temperature sensor, and the oil pressure sensor for the gauge.

Got my oil pan back from sand blasting, painted that.

Looking at the bmw compressors, 4 cyl or 6cyl? Converted to 6 already, do i want to convert back to run the much more compact unit?

Compressor outlet pipe looked dumb, as it would 45 into the side of the engine bay, made a custom one with exhaust flanges and piping.

Using my old Supersprint catback and modifying it with a factory 535i muffler. Using the boysen vacuum actuated exhaust flap to open up to 3" full flow over the stock 2.25", should see an increase of power when in use, otherwise, nice tone and low volume than 3" open.

[Bluebimma]

More test fitting.







Created an oil distribution block for the turbo feed, bmw oil pressure switch, oil temp, and oil pressure gauge.






Creating a new bushing to use the bmw coolant temperature sensor in the ford block. Drill and tap.




The rest of the fuel pieces came in for the rail and pressure monitoring for tuning.





Torque, torque, torque! Brand new 12.9 hardware, fillister, on everything.

[Bluebimma]

Tensioners are expensive, compared to everything else. I broke the pulley back when I first started working on it. Was going to buy a new tensioner, opted for a new pulley and bearing.



Ditched the oversized starter and remote solenoid for a new ford ranger starter with the standard setup. Its more compact and wiring is simplified.



More coolant and oil fittings have been added.




Bmw sensors have been added. Most brackets and components are now in their final position. I think I may time it today.






Never mounted an intercooler before, so heres my first shot at it. I figure the vibrations from the chassis would likely tear the aluminum, so I bought endlink rubbers as insulators. Bought a bunch of brackets from a local hardware store that have 90bends and come powder coated and predrilled for m10 bolts. I plan to mount it to either the radiator support or the front crossmember. From the turbo, it will be 2.25 in and 3" out to the new 3" throttle body. Thinking of Snow performance, any good?

[e30polak]

Nice progress! Also how's the engine fitment with factory turbo placement?

[Bluebimma]

I'll be running into that next week on the test fitment. I think it'll be extremely close, which will limit how big a turbo I can upgrade to and if I need to make a new manifoldz