PPF Turbo forum

Hi, sorry for the English, just felt like sharing this with you experts and get some feedback/input.

Im currently having the S50B30 Motor rebuilt again with forged internals after a total engine loss during tuning.

The car is a 1995 E36 M3 GT #111





The spec this time around will be the follwing (nothing ground braking here)

Engine:
Engine will be a 3.0L S50B30/32 single Vanos HYBRID
S50B32 Engine block bored to 86.5
Forged CP pistons in 8.5:1 (S50B30 trim)
Forged rods from Jaws Motorsport (re-use from last build) also S50B30
VAC motorsport coated cranshaft bearings
BMW Motorsport rod bearings
ARP rod-bolts
OEM headgasket
ARP2000 headstuds (re-use from last build)
S50B32 cylinder head
264°camshafts from the original GT head
Single Vanos from the GT Engine.

FI System:
Twin manifolds made by Jaws Motorsport (ceramic coated)
2x Garrett GT2252 internally wastegated
OEM intake manifold modified for FI in the traditional way
RC 750cc injectors
Walbro 255 in-tank pump
Adjustable FuelPressureRegulator

ECU and Monitoring:
VEMS standalone with full VANOS capabilities
-Launch Control, Flashift, datalogging and other nice stuff (http://www.vems.hu)
Zeitronix wideband:
2x EGT probes, 2x backpressure monitors, Bost/AFR/Lambda and the usual stuff

Other mods on the car are among others:
Suspention:
H/R coilovers and adjustable swaybars
Powerflex bushes
Intrax adjustable camber/caster
Brakes
370mmx38mm Ceramic disks up front with 8piston brembo calipers
E46 M3 rear calipers with drilled disks
Clutch and drivetrain:
Sachs/OMP 6puck clutch
JB-Racing flywheel
2.93 final drive
Interior
Semi stripped interior with a HEIGO halfcage
Recaro PolePosition seats
Schroth 3" harness
Momo wheel
Exhaust
Supersprint De-Cat
Superspring muffler

Car was making about 470hp/560nm at 14psi before. Expectations this time around will be to run it at 18psi maximum making 550hp and 650nm max. The car is a daily driver/trackday car so maximum HP is not the goal, but rather driveable/linear power and usability.

Here are some pix of the current rebuild:
















hopefully I will have some more updates in about 2 weeks time, it would be nice to get yoru input
on this, there is a lot of knowledge in this forum.

Svenni,

I forgot, click the picture to access the photo database, There are folders with pictures right from the day I bought it, through the various upgrades and also after the engine was destroyed.


Engine comming out, totally toast.

welcome to the forum ..

nice projekt.

What went wrong during the calibration?

You should have an awesome torque build up with this setup, do you have a dyno sheet?

Awesome bulid!

Are you gonna run regular pump gas?

MVH Erik

Yes, I will run only pump gas 98okt (or 95). E85 is not available here in Luxembourg and Race Gas not leagal.

xelerator wrote:welcome to the forum ..

nice projekt.

What went wrong during the calibration?

You should have an awesome torque build up with this setup, do you have a dyno sheet?

Here is a Dyno sheet from 2009, at 12psi with no boost control, Dyno at Manthey Racing Nurburgring



Here is one when it was being tuned after a HG change and new Turbos (when it died).

It is not fully known what went wrong, but something surely did, I still claim pre-ignition leading to detonation.

Nice projekt!

I really like the M3 GT! How is the handling and chassi with this much power?

The car is very well planted, specially with the semislicks

http://www.youtube.com/watch?v=LMVKM0OUnP0&sns=em

nice driving

micke999 wrote:nice driving

Thanks

The car had a very tall final drive that time on Spa, I was using a 2.65 from a 325 Diesel which meant that 2.nd gear reached 120km/h and almost 200km/h in 3rd. That limited the wheelspin a lot.

Here is a Video of the car with the 3.15 original diff, its from 2008 when the 1st version of the Twin Turbo system was installed and the car was making about 400hp.

0-200 run
http://www.youtube.com/watch?v=46bBtdtWo24

And here is the car in 2009 with version 2 of the system, 470hp/560nm and also the 3.15 diff
http://video.google.com/videoplay?docid ... 071542790#

Having some fun with an E92 M3, my tires were pretty bad, only 225 up front and 245 in the rear, regular road tires.
http://video.google.com/videoplay?docid ... 9142315002

Engine running again

Now on VEMS standalone ECU (http://www.vems.hu" onclick="window.open(this.href);return false;).

The Vanos (intake camshaft) is fully adjustable now through the VEMS. Also boost control, adjustable from inside the car, Boost by-rev enabled, possible launch control also. Twin EGT's and also backpressure measurement.

Tuning will be done in about two weeks.

Im hoping that by adjusting the Vanos we can gain from the quick spool and torque, and then at higher RPMS slowly fade out the VANOS function to keep the top end power

Engine:
3.0L S50B32 Single Vanos
S50B32 Block
S50B32 Cylinder head
S50B30 Crankshaft
S50B30 spec forged CP pistons @ 8.5:1 compression
S50B30 spec forged JAWS Motorsport (http://www.jawsmotorsport.se" onclick="window.open(this.href);return false;) connection rods.
750cc RC injectors
VEMS managed

ViDEO http://www.youtube.com/watch?v=nLkWQq5-do0" onclick="window.open(this.href);return false;

Nice car and engine! Is the Vanos able to be fully adjusted with the CP Pistons clearance? What camshafts do you use?

johankihl wrote:Nice car and engine! Is the Vanos able to be fully adjusted with the CP Pistons clearance? What camshafts do you use?

The Vanos is adjustable within the parameters that BMW specifies on it at least, but it means that we can manipulate when it kicks in and more importantly when it kicks out.

The cams Im using are the stock S50B30 GT spec, 264 I think.
The cams have 11.25mm lift.

I know this is quite mild power compared to what you guys here are used to but it seems to be very usable power on track driving, and drifting.

Here are the results of the Dyno session.



Low boost setup is around 0.75Bar through the revs.
Max HP is 442 and the car is basically at 440hp at 6000rpm
Max Torque is 431ftlbs (580nm) but at below 4000rpm.

Dyno sheet:



High boost setting is climbing to 1.2Bar at max torque, then dropping to about 1.0Bar at the high rpm's. Reason for this is the buildup of backpressure and the turbos run out of breath. Also, the torque had to be limited to below 500ftlbs because the clutch started slipping, even with a clutch that is supposed to be rated 700nm.

Max HP is 488.1hp (or 490) at 6300rpm (rev limiter set at 7200rpm)
Max Torque is limited to 489.4ftlbs but delivered at c.a. 3.700rpm!

At 3000rpm the car is making more power now that it did at the redline when it came out of the factory

Dyno sheet:

nice!! vanos is the shit!!

How to spend Christmas and the new year

Got my car back on the 16th of December from it´s 11 month stay in the UK. Unfortunatly upon arrival it was not compleate or at least good enough by my standards, so I deceded to pull the engine out. There were two gaskets missing from the rear turbo which could not be accessed with the engine in.
Also the Crankcase went was not routed the right way and had blown out the valvecover gasket and spilled oil everywhere.

Since the engine came out I decided to paint the engine bay. I started off by fixing some of the damage, sanding down and so on, but did not want to use filler and I don’t know how to weld. After the first layer of piant (with a professional gun) I saw that the glossy effect would not really bring out the best of the damages on some of the panels, so I shot 2 coats of flat clear coat.
However, I did not like the flat finish on the struts so I went back to glossy for the struts, which ended of being a semi glossy finish. I kinda like the result, specially after the install of the motor.

Let the fun begin.. December 17th.. My first ever “engine out” operation. Remember that I am not a mechanic:D Extensive use of Ziplock bags and painters tape to mark everything..








Engine comes out on December 18th. Got some help from a local friend! My 9year old daughter on the camera








Me:


Ready for some treatment...


Since I had access.. why not paint!


This is where the valvecover gasket had blown out of its place due to crankcase pressure.




The reason why the engine came out, missing gasket on the downpipe, also missing a gasket on the exhaust hausing....


Looking forward to the install


Biggest Xmas packet in my house! December 22nd.
Primed:




Painted:








The gun.






3 coats of paint.. looks good but the pictures don´t really catch the imperfections on the fenders.. Custom stickers also in place










Flat finish.. too flat in my opinion..








Finished article, semi glossy struts, with Flat/matte finish on the rest. I raelly like it.









Motor back in place on the 26th


Face back on the car, waiting for a new front windshield.


VEMS in place and the MAP sensor hose going through the lid, so I can now close it properly


Catch can fastined, and the vent now routed into the air intake pipe, before the front turbo and after the KN cone.




I also used the opertunity since painting to cut a bit from the inside fender to be able to fit 3” intercooler piping.


Also installed a Z3 shifter which is a great addition! Amazing feel.



Flushed the brake system and put a new batch of ATE super blue racing fluid, also change the oil to the Castrol M-approved 10W-60



I also had a broken front windshield so I had that replaced on the 29th.










My assistants in the garage.




Supersprint exhaust installed, this is a new upgrade.



Just before the new year the engine went back in, clean, with a new valvecover, modifited crankcase wentilation, the two missing gaskets installed in the rear turbo and some other small things.
The past days I have been chasing away the last of the oil leaks, on on the oil drain flange on the front turbo and a second one on the front of the engine where the cylinder head meets the camshatf tray.

Some pictures:
The oil leak on the front of the engine




Old faithfull.. silicone gasket


It was missing a hexagon bolt here, which might have caused the leak




And this bolt was also not tightened.


Faulti gasket, also the flange was not flush so I grinded it down using a 180 paper, followed by a 500, and installed a new gasket, I hope it has solved that leak.

Ready (again) taking my 3year old son for a ride

Nice looking car!