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Thread: E46 330i Automatic - M54B30 Turbo

  1. #1
    Join Date
    Jul 2005
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    2001 330i

    E46 330i - M54B30 Turbo with Meth and Nitrous

    I'm going to skip through a lot of details, so if anyone has questions, I've probably got pictures to explain, so ask away. My photobucket account has over 1,800 photos for this build so far.

    The 330i before I shipped it from Berkley, California, to PEI, Canada:



    The first thing I did with it:





    I drove it around for a bit, put a 4.10 LSD from the black car in it, then decided to put a Technique Tuning turbo kit on it and do the oil pump nut:









    On the dyno heat soaked, with a 6 psi WG spring because of the transmission:



    So that was Sept. 2010.

    In December this happened:



    ...and I haven't had it back on the road since then.

    What started as a parts car for the 330Ci race car rebuild, turned into a nice street car that I couldn't justify stripping down....and then I got carried away with the quick grocery getter concept.

    Welcome to 4 years of out of control upgrades.
    Last edited by PEI330Ci; 07-03-2017 at 04:27 AM.

  2. #2
    Join Date
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    SR-71 Blackbird
    Been following you on E46fanatics.com already.



  3. #3
    Join Date
    Jul 2005
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    My Cars
    2001 330i
    M54B30 engine tear down:



















    Cylinder bores after 75k miles:



    Preparing the block for shipment to the machine shop:



    Goodies to go with it:



    Brand new OEM/GSR Oil pump assembly:











    Shipped the transmission to APT for complete rebuild with upgraded valve bodies and TC. Received it back in 4 weeks:



    For those that are interested, this is what they do:

    • Valve body is custom calibrated to provide the ultimate in clutch application power and clamping force. Clutch apply time is greatly reduced and inadequate, sluggish line pressure rise is totally eliminated (The valve body modifications performed by us are of a proprietary design and are unavailable elsewhere).
    • Hi Energy friction plates and IPT laser cut, surface treated 1008 steel plates are installed in all shifting clutches.
    • *NEW FEATURE* We have now developed the industry's only 7 friction disk C clutch pack, 6 friction disk E clutch pack and 6 friction disk F clutch pack for a tremendous increase in second, third, fourth and fifth gear holding capacity.
    • New one way clutches (sprags) are installed in all locations
    • Upgraded Reverse Drum installed in all units
    • Planetary splines are heat treated to prevent stripping.
    • Cryogenic treatment is applied to input shaft and planetaries to eliminate stress related failure
    • Sun shell is heat treated to prevent stripping
    • Lube system is redesigned to provide increased flow and cooler operation
    • Lock up system is revised to improve converter clutch application, clamping force and torque holding capacity.


    - - - Updated - - -

    Custom diff with 8 clutch centre carrier, asymmetrical ramping, and solid output shafts:



    A little trip:





    More goodies to install:



    Whooops:





    Engine parts came back from machine shop. OEM Rods were balanced and machined for true-ness:





    Serious work on the back of the car:







    Exhaust supplies:



    Stewart pump:



    Oil distribution block:



    S54 chain tensioner on the right:



    ATI Superdamper with A/C drive pulley:





    Turbo oil scavenge pump:



    Chassis back from fab work:









    Engine block back from machine shop semi-assembled:



    Adding bits:











    Erland Cox ported cylinder head with Supertech valves, (34mm/30.5mm) Schrick double valve springs, Schrick locks and retainers:







    Schrick 272/256 cams:



    Oil return bung for scavenge pump:



    Lots more stuff on there:





    GTX3076R turbo mock-up:



    Coolant feed for turbo CHRA:





    Putting the engine in as a mock-up device for exhaust fabrication:



    Interesting perspective:



    It "looks: like lots of room:



    I found out later it wasn't....

    And on the back side, I had a rather large transmission oil pan to deal with:



    - - - Updated - - -

    Quote Originally Posted by auaq View Post
    Been following you on E46fanatics.com already.
    This will be the Cliff's notes version, without numerous changes of parts and re-fabrication.

    - - - Updated - - -

    Aquamist HFS-6 tank:



    Some kind of high pressure bottle:



    Got bungs?





    New 800+ CFM air filter on the left, turbo kit air filter on the right:



    Exhaust fabrication:













    ...which involved a little bit of trial and error with the chop saw:



    Custom DSS half shafts:



    Bosch Motorsport injectors:







    Ok...I'm going to cover a little bit of re-work:





















    11mm timecerts

    - - - Updated - - -

    I decided to increase the size of the WG being used, and also port the turbo manifold to match the exhaust ports. It was not easy, and having done it, I wouldn't do it again. (I think the same amount of effort could have gone into a tubular manifold with better results)

    To start with, I had custom SS wastegate flanges made for 1.75" pipe.(Tial 44mm WG) Then I started grinding:















    Then I started on the exhaust port runners:





    I tried using the die grinder, but there was just too much material to clear, so I moved to something bigger:



    It took a while:







    Then I shipped the manifold and turbine housing for ceramic coating, and they came back pretty:


  4. #4
    Join Date
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    In on 1.
    Contact us for all of your fabrication needs!
    Ride4life1500@gmail.com
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    Instagram @LUXFAB_Colby

  5. #5
    Join Date
    Jul 2005
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    2001 330i
    More parts on the car:





    Assembling the engine again:







    Taking a little step back, the manifold as received back from coating:









    Machining the compressor housing for a turbine speed sensor:





    Turbo installation:











    Surge tank plumbed:



    Brackets for power steering pump and turbo scavenge pump:







    Turbo oil and water lines done:





    Tearing down the "just rebuilt" transmission:



    Because I wrecked some stuff during mock-up:





    And now I know what's in there:



    The part that I wrecked back from machining:



    On the up-side, I added -10 AN fittings to the transmission case for the oil cooler circuit:



    Plumbing in the Meth system:



    Transmission and engine oil coolers:



    Building the engine oil cooler mount:







    Transmission oil cooler mount:



    Fab'd up some mounting brackets for the transmission cooler fan:



    Assembled:









    Engine oil cooler:



    Custom engine oil filter housing:



    For a BIG filter:







    Mounting point:





    I think we need more AN lines:



    Severe frustration with SS fuel rail:



    And incorrectly supplied starter solenoids:



    Those 2 items combined cost me about 2 weeks of free time....


    But then everything got put back together:







    And I started the car.

    But then another project completely occupied the next 6 months of my free time:



    - - - Updated - - -

    The 330i project got a new home.

    It would have been relatively simple if I had stopped the build-out here:





    But I have a hard time doing things half-assed, so this happened:





    Then this:





    And this:





    So when the 330i arrived it looked like there would be some space to work:



    Nope:



    I've had a little bit of time to organize things since then:



    ...and there has been a fair amount of progress on the car that I'll continue with tomorrow.

  6. #6
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    Euro e36 M3 3.2 cabrio
    Nice stuff!

  7. #7
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    1998 e36
    Great photos. I am doing turbo automatic E46 also. Why did you use ZF transmission? Even upgraded D clutch is still weak design. BMW improved the GM transmission on 4/2003+ they never brake from normal use and much better design than crappy ZF.

    What is also surprising is that E46 weighs very similar to E36.

    http://forum.e46fanatics.com/showthread.php?t=1057342

  8. #8
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    E30 M50B28 Turbo
    Nothing but greatness here. Carry on!

  9. #9
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    Quote Originally Posted by hakentt View Post
    Great photos. I am doing turbo automatic E46 also. Why did you use ZF transmission? Even upgraded D clutch is still weak design. BMW improved the GM transmission on 4/2003+ they never brake from normal use and much better design than crappy ZF.

    What is also surprising is that E46 weighs very similar to E36.

    http://forum.e46fanatics.com/showthread.php?t=1057342
    Thanks

    I didn't chose the 5HP19, that's what came with the car. If it proves troublesome, I'll either engineer a solution, or change it out for something MUCH more robust. (I would like to eventually have something with a transbrake) Also, I'm running a stand-alone transmission controller, so it's not going to behave exactly like an OEM transmission.

    I've added a lot of weight to the car since I first got it; I'm almost afraid to weigh it again....but I'm going to have to do that shortly to set up the suspension.

  10. #10
    Join Date
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    E34 525i
    Did you simply reuse m54 rods? Seems weird especially on such an all out build. Granted if you know something I don't please enlighten me for my set of b30 rods.

  11. #11
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    Quote Originally Posted by Hofmeister View Post
    Did you simply reuse m54 rods? Seems weird especially on such an all out build. Granted if you know something I don't please enlighten me for my set of b30 rods.
    That's a good question, and one that has resurfaced in my head over time as well. I certainly wasn't limited by budget at the time of making that decision, so an explanation is probably useful.

    It's RPM that kills rods, (Rod stretch) and more specifically with OEM parts, the rod bolts stretch. I kept the OEM rods, and added ARP rod bolts in addition to the balancing and blue-printing.

    Being that they (B30 rods) are a forged evolution of the M52B28 rod that has proven over 600rwhp on Cardcounter's car....I didn't think there would be an issue with my modest power goals. (430+rwtq through the automatic transmission)

    I have also been working on another M54B30 engine build in parallel to this one, so I didn't see the point of going too crazy on something that would eventually be replaced.

    The point of most of this car is proof of concept, and getting instrumentation/electronics in place to move forward with the "B" engine.
    Last edited by PEI330Ci; 11-20-2014 at 11:38 PM.

  12. #12
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    Awesome build and garage

  13. #13
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    E34 525i
    Ok, I was thinking much larger goals than 430rwtq. I can see the rods doing well in that scenario.

  14. #14
    Join Date
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    95 M3T, 02 M5, 02 Cummin
    Impeccable, well done Pei! A shop built nowadays has to have living quarters up above.
    Last edited by iRodD; 11-21-2014 at 12:37 AM.

  15. #15
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    2 e30's
    Real bosch motorsport part numbers start with a "B" your injectors are production parts.

    XD

    All in all it looks better than the first go around!

  16. #16
    Join Date
    Jul 2005
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    2001 330i
    It's amazing how much ground clearance you "think" you have when the car is 2 feet up in the air on jack stands. I won't justify my mistakes other than to say that I had a packaging issue that I was struggling to solve, and I F'd up.

    When I parked the 330i on my driveway, I found out pretty fast how little ground clearance I really had:





    The coupling on this charge pipe was loose, so it slid down about 2" more than the desired position, but it still was silly low:



    I also found a major clearance issue between the front sway bar, and steering rack, and the 4" turbo inlet pipe. So....back to the pipe fab.





    WG re-location:









    Not a lot of room under there:





    Revised 4" turbo inlet pipe:











    Revised 2.5" charge pipe from turbo to IC:



    On the car:







    And we have ground clearance:





    On a low car:



    - - - Updated - - -

    Quote Originally Posted by Mr Deagle View Post
    Real bosch motorsport part numbers start with a "B" your injectors are production parts.

    XD

    All in all it looks better than the first go around!
    Bosch Motorsport Website:

    http://www.bosch-motorsport.de/en/de/produkte/catalog_products_1_167570.html

    Bosch Motorsport PDF:

    http://www.bosch-motorsport.de/media/catalog_resources/Injection_Valve_EV_14_Datasheet_51_en_2775993867pd f.pdf

    And then order from Bosch Motorsport in Michigan.

  17. #17
    Join Date
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    6465 328ti
    As usual, Amazing build and great documentation as well as attention to detail! Badass garage build too! I've alwaays wanted to go to PEI but this is as close as I got:



    Anywho, looking forward to seeing the progress!

  18. #18
    Join Date
    Jul 2005
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    2001 330i
    PCS-2000 Transmission controller and Motec M150 ECU next to the DME:



    Bye bye OEM wiring harness:









    M150 location:



    10 Thermocouples for the engine block and cylinder head:









    More fabrication:







    More wiring stuff:























    Bracket:









    Paddle shifters for transmission:











    Digital master power relay:



    - - - Updated - - -

    Lifeline Fire stuff:











    Dash panel:











    More stuff:



    Rear PFC caliper vs OEM:





    Front PFC caliper vs OEM:





    Front PFC rotor vs OEM:





    I never thought I'd be so happy about bottles:



    Suspension bits:











    Trial fitment:



    More wiring stuff:







    Converting Lifeline fire system controller to Autosport connector:





    Cutting dash and mounting Motec SLM:









    Potting Honeywell switches with RT125:



    Adding heat:



    Rear Fire/Cut-off switches ready for installation:



    On the car:



    Junk in the trunk:







    Solid state relays, and Meth control valve / flow sensor with DTP/DTM connectors:



    Their new home:



    More sensors to mount:



    - - - Updated - - -

    Modifying the FPR to accept a 3/8" NPT adapter for fuel pressure sensor:













    Fuel temp on surge tank:



    Bosch coolant temp sensor:



    Bosch Oil "return" temp sensor after oil cooler:



    Oil temp and pressure from the block, before oil cooler:



    Engine coolant pressure sensor:



    Crank case pressure sensor:



    Pre-turbo and post-turbo air temp sensors:



    Exhaust manifold pressure, and Compressor outlet pressure sensors:



    EGT:



    Manifold pressure sensor on the manifold plenum, post-IC air temp sensor, and pre-TB air temp sensor:



    The idea behind those 2 air temp sensors is to be able to measure temperature change when injecting nitrous and/or meth.

    Nitrous pressure sensor on the solenoid:



    More dash switch mounting:





    Unfortunately, the holes have to be offset like that for the switches to fit. I'd rather keep the OEM dash so....





    Cementing one of the thermocouples to the engine block:



    There will be a sensor between each pair cylinders.

  19. #19
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    You need a MoTeC system exhaust. It's not a bad way to spend ten thousand dollars.

  20. #20
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    Umm.. wow

  21. #21
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    1991 BMW 325i
    I had to log on just to say that you are F*CKING BONKERS. This is awesome, and I dream of something like this. Dude could buy a Ferrari and he builds an awesome 330 auto for a street car. Like nothing I've seen before.

  22. #22
    Join Date
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    Can't believe there aren't more replies -- I've been reading threads in here for 8 years, this is maybe the coolest/most thorough build I've ever seen. So awesome to see all the little details. The amount of data you will have on that car is incredible!

  23. #23
    Join Date
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    E36 Turbo
    Holy hell... that's a pretty epic build! Just my kinda thread too... lots of pictures, pretty ones at that.

    E36 DYNO TUNING WIRING PARTS

  24. #24
    Join Date
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    Quote Originally Posted by PEI330Ci View Post
    Bosch Motorsport Website:

    http://www.bosch-motorsport.de/en/de..._1_167570.html

    Bosch Motorsport PDF:

    http://www.bosch-motorsport.de/media...5993867pdf.pdf

    And then order from Bosch Motorsport in Michigan.

    So that makes my ignition coils whiz bang motorsport parts as well.

    http://www.bosch-motorsport.de/en/de..._1_167491.html

    Wrong, they are Mercedes production parts.

    Your injectors are probably off of an alternative fuel vehicle of some sort.

    Take for example this valve:

    http://www.bosch-motorsport.de/en/de..._1_167590.html

    That is a real motorsport part, not used in a production car. Hence the "B" prefix, and the silly pricetag.

  25. #25
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    e36 m3, turbo e36
    Simply amazing. Thank you for sharing!


    -sold...replaced by turbo e36

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