Turbo Exhaust Manifold

[Lay2Low]

Where is the best place to get a custom turbo exhaust manifold done? Also, how far off is the E36 turbo manifolds to the E46? I have a 2.5L 323.

[Oshin02]

Where is the best place to get a custom turbo exhaust manifold done? Also, how far off is the E36 turbo manifolds to the E46? I have a 2.5L 323.
As far as I see, the E36 turbo manifold has the same bolt pattern as the 323, 325, 328, and the 330. The position which the turbo will sit is the same, so not all of a differance.......

[Gilb3rt0]

Yea it does bolt up the same. U could use any of the turbo manifolds the e36 crew is rocking. But the problem isnt making your own kit, its having management to run your kit.

[Lay2Low]

Sounds encouraging. I know that there is a lot of complex issues with the turbo for the E46, but the manifold seems like the biggest physical problem. Turbos, intercoolers, etc will have to be researched in terms of buying the correct one, but if nothing "extremely custom" has to be fabricated, it seems more possible.

And yes, the problem with the turbo is the management... haha
...But it looks like those problems are being figured out.

Also, which manifold am I best off getting if I am going to go through with the turbo? 2.5L? m3 manifold? Thanks for everything guys!


**Also, sick car!

[Gilb3rt0]

I have yet to find out any mangement system that runs with the stock ecu on our cars. Im running tec3r which means i have no luxeries in my car hahaha. So if you like your ac or traction control than stand alone engine management might not be the thing for you. But as far as manifolds go I say go with whichever one flows better. I hear the technique tuning manifolds pretty sweet.

[Synonymous]

Here's a turbo manifold that will work for our cars: http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1,1&item=7989334280&sspagename=STRK%3AMEWA%3AIT I like this one because it's cast-iron so it's more durable and it also has a flange for an external wastegate. I don't have any trouble with making the hardware portion of a turbo kit, ie. intercooler piping, oil lines, exhaust, etc... The only issue I have is with fuel management. I need someone that can perform software tuning with a turbo.

[Lay2Low]

Here's a turbo manifold that will work for our cars: http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1,1&item=7989334280&sspagename=STRK%3AMEWA%3AIT I like this one because it's cast-iron so it's more durable and it also has a flange for an external wastegate. I don't have any trouble with making the hardware portion of a turbo kit, ie. intercooler piping, oil lines, exhaust, etc... The only issue I have is with fuel management. I need someone that can perform software tuning with a turbo.


That is exactly what I am saying. I wonder if http://forum.e46fanatics.com/showthread.php?t=294039 will work with the turbo app? Also, will running low boost at first (like 3-4 psi) throw a lot of fault codes and things like that? With such a low boost before the engine management is taken care of, will it extremely negatively affect the engine? Also, if you could do it, what parts would you go with for the ideal turbo set up?

[Gilb3rt0]

Tsi might work. Do you know of anyone that can tune it in the us? I mean I really havent heard of that engine management. Ive only heard it from da motorsports.

[Lay2Low]

It is as foreign to me as it is to you. By the way they are making it sound, it seems that it is a "piggyback" system and is laptop programable. From what I can gather, it seems the mapping is done by the user and is pretty plug and play with some good how to... but again if it were only that simple, right? hah

What do you think about running low boost until programming is figured out? Will it just be a waste to have all components in place w/o software? I know I will not be seeing huge gains, but boost can be turned up, etc.

[Synonymous]

That is exactly what I am saying. I wonder if http://forum.e46fanatics.com/showthread.php?t=294039 will work with the turbo app? Also, will running low boost at first (like 3-4 psi) throw a lot of fault codes and things like that? With such a low boost before the engine management is taken care of, will it extremely negatively affect the engine? Also, if you could do it, what parts would you go with for the ideal turbo set up?

Here would be my setup:
I would use that cast-iron manifold for durability. The Garrett GT series ball-bearing turbos are nice but they're $$$$. I would probably used a T3/T4 hybrid turbo. They're about half the price and still flow very well depending on the A/R. I would definately make a bracket to support the heavy manifold & turbo. I made a turbo kit for my previous car and the flanges warped because I didn't have a bracket supporting the turbo. 2.5" intercooler piping with bead-rolled ends so the silicone connectors won't pop off or leak under boost. Front-mount intercooler with water spray. The wastegate would be a Tial 38mm unit. Tial wastegates are awesome, never had any boost spikes with them. Recirulating bov so the MAF signals won't make the ecu go crazy. 3" downpipe with a 3" metal core cat and full 3" exhaust. All factory O2 sensors will be installed to keep the ecu happy. Colder spark plugs, probably NGK coppers. Assorted gauges and other odds and ends... I'll probably run 6-8 PSI, 3-4 PSI is really nothing. A clutch upgrade, like the UUC ceramic/kelvar unit, is inevitable with the extra power.

As for fuel delivery, I thought of several options.

1. You can use a FMU/rising fuel pressure regulator to add extra fuel. However, I'm not sure if the newer E46 models still have a fuel return line. Without the fuel return line, the FMU can't be used.

2. Additional fuel injectors mounted in the intercooler piping, just prior to the throttle-body. It would be controlled by a separate fuel injector controller like a Greddy Rebic.

3. Bigger injectors, but this will require software tuning. My number one choice for fuel delivery but custom software tuning for turbos isn't available, at least for now.

4. I also found this Apexi Afc that's designed to be used on our BMW's. http://cgi.ebay.com/ebaymotors/APEXi-AFC-SELECT-BMW-328i-328ci-330i-330ci-M3-E46-NEW_W0QQcmdZViewItemQQcategoryZ33597QQitemZ8001888822QQrdZ1Q QsspagenameZWDVW It'll probably have to work in conjunction with a Fmu or bigger injectors to provide enough fuel.

My car will be turbo'd....someday.

[Lay2Low]

Here would be my setup:
I would use that cast-iron manifold for durability. The Garrett GT series ball-bearing turbos are nice but they're $$$$. I would probably used a T3/T4 hybrid turbo. They're about half the price and still flow very well depending on the A/R. I would definately make a bracket to support the heavy manifold & turbo. I made a turbo kit for my previous car and the flanges warped because I didn't have a bracket supporting the turbo. 2.5" intercooler piping with bead-rolled ends so the silicone connectors won't pop off or leak under boost. Front-mount intercooler with water spray. The wastegate would be a Tial 38mm unit. Tial wastegates are awesome, never had any boost spikes with them. Recirulating bov so the MAF signals won't make the ecu go crazy. 3" downpipe with a 3" metal core cat and full 3" exhaust. All factory O2 sensors will be installed to keep the ecu happy. Colder spark plugs, probably NGK coppers. Assorted gauges and other odds and ends... I'll probably run 6-8 PSI, 3-4 PSI is really nothing. A clutch upgrade, like the UUC ceramic/kelvar unit, is inevitable with the extra power.

As for fuel delivery, I thought of several options.

1. You can use a FMU/rising fuel pressure regulator to add extra fuel. However, I'm not sure if the newer E46 models still have a fuel return line. Without the fuel return line, the FMU can't be used.

2. Additional fuel injectors mounted in the intercooler piping, just prior to the throttle-body. It would be controlled by a separate fuel injector controller like a Greddy Rebic.

3. Bigger injectors, but this will require software tuning. My number one choice for fuel delivery but custom software tuning for turbos isn't available, at least for now.

4. I also found this Apexi Afc that's designed to be used on our BMW's. http://cgi.ebay.com/ebaymotors/APEXi-AFC-SELECT-BMW-328i-328ci-330i-330ci-M3-E46-NEW_W0QQcmdZViewItemQQcategoryZ33597QQitemZ8001888822QQrdZ1Q QsspagenameZWDVW It'll probably have to work in conjunction with a Fmu or bigger injectors to provide enough fuel.

My car will be turbo'd....someday.



Awesome response. I think I am going to go after it. I basically need to create a "shopping list" of everything I might need. Can someone try and think of everything I might need. I am too tired to think about it tonight, but I would like to have something to ponder over tomorrow. Thanks a lot for everyones input again! :clap:

[Lay2Low]

Also, what is the deal with oil/oil lines for the turbo? Any little tips that you experienced guys have would be great to here. *Note: no, I am not doing this completely by myself, but I would like to know as much as I can.

[Gilb3rt0]

If I were you Id stop looking for parts for a kit and research on a working management for our cars. If you want to go with the tsi make sure that you have someone that can tune it nearby and find out everything you can about it. I dont want you having the same problem I did because of no management. Also our cars dont like low psi with no programming or atleastmine didnt and I was only running 5 psi.

[Lay2Low]

Thank you for the advice. I think I am going to be alright with the management, as I have been talkin around today and a good friend of mine has a close friend that is a software programmer for a race team in Long Beach. He will for sure be able to do the mapping, but just as everything goes it costs $$$