Guys, I'm addicted! Euro M3 Turbo from Poland

[Maleckis]

Hello!
Some of you may remember me but still I would like to introduce myself at the beginning. I’m Christopher and I come from Poland. I have already turbocharged my European version of E36 M3 S50B30 which I have been having for over 2 years.

256.1 HP & 298.1 Nm – soon after buying,
283.1 HP & 314.4 Nm – new lambda sensors, new air filter, new MAF, SuperSprint front exhaust without a catalytic converter.

Firstly we removed all needless parts such as an air conditioning, a carrier, an air pump, a carbon filter housing, a few hoses and sensors etc. The turbo-charging lasted almost 2 months. The engine was completely untouched and stock until nowadays. A compression ratio was equal to 10.8:1. The M3 is boosted by GT35R (0.4bar ~ 6 psi). The turbocharger is situated at top mount turbo exhaust manifold.

• Specs:
  
  - Stock euro S50B30 (CR=10.8:1),
  - Garrett GT3582R turbocharger,
  - Home-made turbo exhaust manifold,
  - Home-made 3” down pipe,
  - No name 45mm waste gate,
  - SuperSprint front exhaust without a catalytic converter,
  - Stock rear muffler,
  - No name 100mm air filter,
  - Air to air intercooler 28"x9"x2.75",
  - Polish 50mm BOV,
  - Customized intake manifold,
  - Volvo 450cc/min. injectors,
  - Walbro GSS 340 fuel pump in fuel tank,
  - Stock fuel pressure regulator,
  - 0.4bar chip from Sweden,
  - Defi EGT & Auto Gauge boost sensors.

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[Maleckis]

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As you can see we remained a stock intake manifold and an air duct. We had to modify that because the air duct popped out from intake manifold’s flange at approximately 3 psi. We also replaced a stock fuel pump with Walbro GSS 340 then. At 3rd gear we couldn’t increase amount of fuel over 12.5:1 because the stock fuel pump wasn’t so efficient.

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41. Walbro GSS 340 vs. stock Bosch fuel pump


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Unfortunately, after almost thousand of kilometers without any breakdowns the head gasket has gave up because of its old age. A cylinder head was given to a local cylinder head service. It has been already cleaned and flow tested. It is airtight and flat. All 6 pistons are in very good condition – no symptoms of knocking etc. An engine block also is intact.

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[Maleckis]

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72. Removed carrier


The cylinder head service will replace valve seal rings, port, polish cylinder head, and adjust valves (new plates and cam followers). Except for lower CR steel head gasket I must buy a new waste gate. Mine is leaking.

Best Regards,
Christopher.

[bmwperson]

nice

[savage217]

That thing is awesome. You got any vids?

[jekaio]

intake manifold looks awesome.

you should color match it to the car!!

[dcvee]

Very nice Christopher! I'm surprised that with stock motor mounts your turbo isn't bouncing off your inner fender...or maybe it is?

Nice job on the manifolds too.

Don

[a32guy]

Looks like alot of work! Was that fun?

Nice car. If you feel like giving up, I'll trade engines with you.

[Maleckis]

Oh, I almost forgot about one of the most important pictures:



An adequate marking of a car is a base.

[bmwperson]

Oh, I almost forgot about one of the most important pictures:



An adequate marking of a car is a base.

rotfl i got the same badge on my m3

[abq]

mmm i love the individual trottles so sexxy. and nice work for a diy. do you have pics of how you built the intake manifold? peice by peice

[Streetcar]

Nice build up...

You may get some irratic fueling because of the diameter expansion infront of the HFM. Try to double the diameter in straight length before and behind the HFM. For example, a 3" HFM should have 6 inches of straight piping with constant 3" diameter before it.

Other then that, fab works looks great!

[Jean-Claude]

Aren't Euro M3's equiped with ZKW headlights? Why are the headlights pictured here not as deep?

[camshaft]

Awesome job, I'd love to have that in my car!

Austin

[Maleckis]

rotfl i got the same badge on my m3

I was thinking about "318iS" but it would be too fast for me.

mmm i love the individual trottles so sexxy. and nice work for a diy. do you have pics of how you built the intake manifold? peice by peice

That’s stock aluminum intake manifold. We had to customize it because of an air duct. We cut stock flange off and welded 5mm plate. Then we made new flange for the silicone elbow. We also closed openings of 2 hoses which are connected to the manifold in stock.

That is how it looks on the other side:

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Thank you for pleasant words. The cylinder head should be finished on Tuesday. If I have time I will pick it up.

Best Regards,
Christopher.

[GodFather]

Damn, that thing is just amazing!!!
I freaking love how the wastegate just dumps!!!! HAHAHAHA that pipe is th ebest!!!
Great job on your car man!!! It loks amazing...
we need some vids on them rainy roads

Stan

[liquidtension]

great project, thanks for the extensive pictures
goodluck on the cyl head assembly

[tlmitf]

that bought a nice smile to my face

great to see someone out there, just working away - loving what they have

[Maleckis]

Today I got back my cylinder head from a machine shop. Firstly it was cleaned and flow tested. The cylinder head is airtight and flat. Guys from the machine shop ported and polished the head (valves too as well) replaced valve seal rings, retainers, a few cam followers and adjusted valves.

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I took pictures of blown head gasket and I want to show you them. I think that was happened because of its old age. What do you think? As you can see the head gasket is rotten (I don’t know if it is a suitable word) near water ducts in a cylinder head. Maybe people who had this M3 before me weren’t looking after her properly. Sometimes (when the M3 was N/A) there was a slight smoke getting out of exhaust pipes, especially when weather was cold. Maybe 0.4bar of boost killed her ultimately?
AFRs at WOT were 11.2 to 11.7. However, I had 2 over-boosts during adjusting a waste gate (10 psi at AFR equal to 12.5 which is too lean). That could be another reason of blown head gasket. The head gasket gave up finally at 0.4bar at WOT at 4th gear when everything was OK.

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That thing is awesome. You got any vids?

That's funny, but I have only one. A lot of smoke getting out of exhaust pipes after blowing of the head gasket .

In the next week I will receive money for few M3 parts I have sold recently and I will order a head gasket then. I hope I’ll put together everything (with new waste gate. By the way, I’m thinking about buying the Turbonetics’ racegate.) before New Year. If you are interested, I will describe here my all steps.

Best Regards,
Chris.

[highboostingm3]

I love it! Euro with top mount big pimpin' custom DIY!

[Streetcar]

Hi Chris - Do you happen to have the flow numbers from the heads?

[e28forlife]

If you are interested, I will describe here my all steps.

Best Regards,
Chris.

Please do! This is a great project and I'm sure everyone here would like to follow the progress.

I like the custom exhaust manifold and downpipe, did you fabricate (weld) it yourself?

[Dinan S3]

sick ride....i didn't catch if you mentioned any #s ....whats she puttin down?

[Wojtek79]

spoko fura....

[Maleckis]

Hi Chris - Do you happen to have the flow numbers from the heads?

I probably used wrong words. My English isn’t so good. A machine shop flow tested a cylinder head to see if it is airtight. From what I know, there is only one flow bench in Poland and a using it is a bit expensive. That’s why I abandoned the idea of checking an air flow.

This is a great project and I'm sure everyone here would like to follow the progress.
I like the custom exhaust manifold and downpipe, did you fabricate (weld) it yourself?

Thanks. Whole welding was made by my very good friend, who is a gynecologist, by the way .

sick ride....i didn't catch if you mentioned any #s ....whats she puttin down?

I haven’t dynoyed her yet. When I put the engine together I will do a dyno test. I hope it will show 350-380 HP.

What do you think about blown head gasket? Was it mainly caused by its old age?

Chris.