Official TSI turbo kit review thread

[e36'n]

Well it's been a while and the kit has been tested. I have learned a helll of a lot from all you guys here and reading through the old threads. Turbo install started just before Christmas 2005 and I started driving it in May. Working full time and being a university student had a lot to do with it taking so long. Waiting for parts to clear customs also contributed to that, as did waiting for them to actually manufacture the parts.

Introduction:

I was the tester for the TSI Extreme Plus kit that Jesse @ Turbo-kits.com sells. After receiving an excellent deal, I started the install by tapping the oil pan, which I really don't want to get into. Let's just say it's not fun, especially when you haven't done one before.

Inside Oil pan.JPG
Picture 136.jpg

Also, here's proof that no matter how high you tap the oil pan, it's not above the oil level.
Picture 403.jpg

Somewhere after going to Hawaii for the first time ever and doing the oil pan/lines/fittings/etc/etc, I started on the manifold which was a complete bitch to do the first time. Trying to get some of those nuts on the exhuast studs was practically impossible without improvising. So for anyone who is planning on installing a TSI manifold while the head's still on (even with the updated version)...have fun. Basically, there's about 6 which won't fit properly unless you grind the nut down, use different nuts or grind the stud to an angle so you can slip the nut on easier (or a combination of all three). The second manifold was much easier as I knew what to do.

After doing the manifold, clocking the turbo about 45 times, I fit the 28x12x3" intercooler. It would NOT fit without modifications to the front bumper or unless I decided to remove the aux fan. I chose to modify the bumper as it needed replacing anyways.

Pic of the fully modified bumper to fit the IC:
Picture 517.jpg

I cut some meter long m8x1.25 studs to mount the IC, by drilling into the nose panel, threading into the IC inserts then using jam nuts to keep them in place. Not the cleanest method, but it definitely works.

Picture 481.jpg

[e36'n]

On to the intercooler piping now.

With the first manifold and spacer it was A BITCH to get above the subframe, which I have to do as I live where the roads aren't great to say the least. Here's some more recent pics of how the piping looks now:

DSC00024.JPG

piping.JPG

After the pre-intercooler piping, I did the post IC piping which took a lot of work. I had to cut the supplied pipes so many times to make it fit.

Post IC piping:
muffler 043.jpg

muffler 040.jpg


After that installed the extra injector block and the fuel programmer, or injunction control unit as the gf calls it. I'm really impressed with the extra injector block, as it fits perfectly and is very high quality. The only negative is that makes that TB arm rub the TB boot, so you have to pull/brace the MAF towards the drivers side fender as much as possible. I used some heavy duty cable ties so it wouldn't rub. Worked fine for me.

muffler 041.jpg

[e36'n]

Two notes:


- Venting the crankcase back into the intake hose was a HORRIBLE idea. So much damn oil on my fresh pipes and IC. Now I have it going into a catch can/filter thing that drips. I'll be using a catch can with a filter on the top of it when I get a chance to change everything around.

- To my surprise, I didn't need to add that much fuel with the extra injector controller. With the controller you can either add fuel based on boost or rpm points. I only had to add fuel from 3000 rpms and up according to my afr's when I was datalogging with my zeitronix wideband. The 10:1 rrfpr had something to do with this I'm sure.


My impression:

With the new manifold this kit would be worth it as long as it's the least expensive (or one of the) around. With the stock chip and the absence of a knock sensor in my 92, I was scared of detonating, but I didn't actually have a problem that I noticed. I was using Husky 94 w/10% ethanol, which some local tuners advise against opting for Shell 91. Worked for me though at the psi.

With the stock chip and only the TSI fuel management, I gained 75whp and 71wtq with a small amount of boost from this kit. I set the wastegate for 6psi, but by peak torque it was at about 5.2psi and at peak hp 4.2psi. I still don't know why the huge boost fall off, but I have to attribute it to the weak spring in the internal w/g.

The turbo I'm using is a GT 2871r 0.86 a/r with the T25/28 style turbine housing. 2" pre IC piping, 2.5" post IC piping, stock MAF in a blow through setup.

Here's the SAE corrected dyno and thanks for looking. I'm out of town for the next couple days, so I won't be able to reply if there's any questions until the end of the week.

Big thanks to Jesse @ turbo-kits.com, Doug @ TSI, AlpinawhiteM3, Techno550, Highboostingm3, Def, Byron and all the other bimmerforum members who helped me along the road and made this possible.


dyno3.JPG

[e36'n]

Bump.

Anyone have anything to say?

[BMWManiac]

Not too shabby...question is, are you happy with it? Maybe see if you can get AA or NickG to remote tune it and get to the 250rwhp/rwtq. I bet it is in that car!

If I was a e36 3 series owner, I probably wouldn't hesitate to pick one up...seems pretty reliable setup.

[JLac]

Maybe see if you can get AA or NickG to remote tune it and get to the 250rwhp/rwtq. I bet it is in that car!

Or how about Techno550 ?

Great job on the writeup. I always knew that oil level was above any spot that you can tap the oil pan. You just showed us some proof of that.

[salvia.D]

at least he had the balls to try a new kit.

[NHbmw325I]

Seems like a decent setup, i'll have to look into this sometime!

[BaLLZacK]

Did I miss something the dyno graph doesn't show much of a gain?

Edit: Forgot that this is not an M3 thats an awesome gain, very nice! the power curve looks like that of a modded M3

[Darth Maul]

are you upgrading the kit?

[e36'n]

Not too shabby...question is, are you happy with it? Maybe see if you can get AA or NickG to remote tune it and get to the 250rwhp/rwtq. I bet it is in that car!

If I was a e36 3 series owner, I probably wouldn't hesitate to pick one up...seems pretty reliable setup.

Definitely happy with it except for that the boost falls off towards the redline. I've tried different wastegates and I have to assume that it will continue until I retrofit an external w/g on. The spring in the internal is probably too soft. I sourced the vacuum signal from the manifold and it didn't change anything either.

As for tuning, I can fully program the obdI DME's especially the 402. I'm sure I'm over the 250 mark with 8 psi and the tuning.

Great job on the writeup. I always knew that oil level was above any spot that you can tap the oil pan. You just showed us some proof of that.

Thanks man!

at least he had the balls to try a new kit.

Tell me about it. It took about five months to get everything fitted properly and that was before I had to test the new manifold.

are you upgrading the kit?

I'm putting in my 42lb injectors, a Tial 50mm BOV, new tuning and an AEM FPR (if the ebay seller stops avoiding me and sends it out).

[highboostingm3]

Q: Did all that end up costing more than $4500?

[e36'n]

Q: Did all that end up costing more than $4500?

Without including the exhaust work yes, but I got a deal as the tester. Do I get a spot in the tried and tested hall of fame now?

[Juicy Double]

will artwar tune your car? I'm curious to see what this kit can do with a solid 6 or 7 psi.

[e36'n]

will artwar tune your car? I'm curious to see what this kit can do with a solid 6 or 7 psi.

Artwar and I will both be tuning it like we have all along. I'll probably run 8.5psi on the stock HG with 91 pump gas.

[byron]

swweetttttttt

[sideshow]

on post #2, pics 3 and 4, what is the regulator looking thing to the right of the BOV and covered in orange rtv looking stuff? thanks

JOEY

[e36'n]

on post #2, pics 3 and 4, what is the regulator looking thing to the right of the BOV and covered in orange rtv looking stuff? thanks

JOEY

A RRFPR that I had to JB weld and use sealant to ensure there were no vacuum/boost leaks.

[highboostingm3]

Do I get a spot in the tried and tested hall of fame now?

You are added. It's easy to let things slip so I am glad you reminded me.

[uber e36]

Great job being the tester, but I think it looks horrible with the bumper cut up and a huge exposed IC... Too bad you can't do something about that.

[mike saunders]

Congrats on the install....

A couple of question, though:

If you're only putting out 8 psi, then why the huge IC? That size core will support flow for twice as many CFMs as you're likely to see. You could have gone smaller easily, but was there another reason? A future turbo upgrade?

Which leads to question 2: Since the GT28 and GT30 have the same size housings (and cost about the same) then why stick with the smaller turbo?

[byron]

Great job being the tester, but I think it looks horrible with the bumper cut up and a huge exposed IC... Too bad you can't do something about that.

it actually does not look that bad in person. looks pretty mean.

[e36'n]

You are added. It's easy to let things slip so I am glad you reminded me.

Thanks man.

Great job being the tester, but I think it looks horrible with the bumper cut up and a huge exposed IC... Too bad you can't do something about that.

I'll be removing the aux fan and putting on either a mesh grill, a winter junk bumper or my M-bumper before winter.

I actually always get complements and thumbs up from the locals. I didn't want to remove the aux fan during the summer so this worked fine for me.

Congrats on the install....

A couple of question, though:

If you're only putting out 8 psi, then why the huge IC? That size core will support flow for twice as many CFMs as you're likely to see. You could have gone smaller easily, but was there another reason? A future turbo upgrade?

Which leads to question 2: Since the GT28 and GT30 have the same size housings (and cost about the same) then why stick with the smaller turbo?

I had three IC options being the TSI tester. One was a 24x3x6.5 core and the other was 24x2x9 and they were both tube and fin, compared to this one which was bar and plate. Either of those would have sufficed, but I figured in the long run this would work best for my goals (350-400whp, bigger turbo, external gate, etc).

I didn't really have much of a choice for the turbo, although I think I could have gone with a GT2876r instead. I actually really like this turbo and it suits the 2.5L quite well. This turbo would be efficient up to 17 or 18psi on the 2.5L.

it actually does not look that bad in person. looks pretty mean.

Thanks bro. Not quite the sleeper look like yours, but it'll do for now

[bimmeracer3]

awesome.
how do you tune a stock ecu and how hard is it?

[Darth Maul]

your piping looks way different than mine. It seems like your hot pipe is opposite to the charge pipe on my set up.