2009 E93 ADE Single Turbo Build

[doublespaces]

There are some differences between the 335is(LCI) and the Pre LCI E92 M Sport:

Pre LCI M Sport

LCI:

I am really hoping everything lines up good enough but I'll find out soon. Notice the brake ducts on the LCI and M Sport are in the center, on the sides of the FMIC. I already have the ducts for the coolers as shown in the photos above.

On the Pre LCI non M Sport the brake ducts are on the side by the fog lights:

And on the passenger side, that vent is split in half where one half goes to the oil cooler and the other half goes to the brake duct. The driver side goes completely to the brake duct only.

Since the LCI and Pre LCI M Sport redirects the brake ducts to the sides of the FMIC, I need to buy the right brake ducts but I'm not sure what the differences are.

These are the LCI brake ducts:
51748047409
51748047410

There are other parts to buy most likely, such as the retainer frames for the ducts but I'm only buying a little at a time to see what works.

 

[Jeffman]

For LCI sedans I think its one of these:

51742157666
51742157678
51742157680

Found here:
https://parts.bmwofsouthatlanta.com/showAssembly.aspx?ukey_assembly=419948&ukey_product=1370480

I've called South Atlanta and they will help a little bit with identifying what parts are for what cars.

You may have to order them from germany and see what shows up in the mail. Otherwise you can call a dealership and ask them to help you with the stuff labeled as #2 in this diagram:

http://www.realoem.com/bmw/enUS/showparts?id=VB73-USA-10-2006-E90-BMW-335i&diagId=03_0208

Thanks, Doubles. My 2008 is pre-lci so I'll take a look online too. I live about 200 yards from a new BMW center in the Philly area and know the parts guy "Bob" pretty well.

 

[R.G.]

Trying to wrap my head around duct, duct goose issue. So is this the goal?
M sport pre lci front bumper E93
Retain fogs
IS cooler ducts
Brake ducts from IS? Or stock brake ducts or?

 

[Jeffman]

I'm not exactly sure what Doubles has in mind, but I'd think he's trying to maximize cooling. For my Pre LCI E90 I'm thinking of going with the OEM aerodynamic front bumper cover (51192149526)

There is also a matched set of OEM ducts, which, by eliminating the fogs maximizes cooling air to the brakes, oil cooler (right side) and coolant/transmission fluid radiator (left side). (51192149516)

 

[doublespaces]

Trying to wrap my head around duct, duct goose issue. So is this the goal?
M sport pre lci front bumper E93
Retain fogs
IS cooler ducts
Brake ducts from IS? Or stock brake ducts or?

Yes you've got it right, except I don't know which ducts. I'm hoping 335is brake ducts fit, but it's all untested.

 

[doublespaces]

I got my M Sport rear bumper installed, with my rear PDC retrofit. I also fixed my backup camera, as the handle camera went out. I also did the hard part of the wiring for my servotronic. The only bad thing at this point, is I have a passenger airbag light on that I need to fix. Thanks to @786dynamics the fitment was great, I'll know on the front bumper soon.

For anyone interested, the retrofit guide is here:

https://bmw.spoolstreet.com/documents/e93-e92-rear-pdc-retrofit.31/

 

[Erichale77]

Interested in a CF diffuser for ur bumper?

 

[doublespaces]

Yep but not until I get my CF decklid. For now I'm just enjoying my painted diffuser.

 

[camberadam]

Interested in a CF diffuser for ur bumper?

Do tell...

 

[Erichale77]

I have a cf diffuser i bought for a M sport or M tech bumper but I found out that I have the very uncommon M euro bumper which wont work. Still in wrapper. Sorry for hi jacking this thread. PM me for details

 

[TWilly]

Interested in what had to be done for the hard wiring for the servotronic

 

[doublespaces]

Interested in what had to be done for the hard wiring for the servotronic

There is a whole thread on it, I just need to run a wire down to the solenoid now from the engine bay. The easiest part.

https://bmw.spoolstreet.com/threads/servotronic-on-a-335i.1400/

 

[doublespaces]

I started doing my front M Sport conversion, the radiator carrier has to be trimmed a little bit to fit the M Sport brake ducts. I have a multi-tool and I already cut quite a bit out from installing my FMIC already, so this only took a few seconds on each side:

And here is the duct installed:

And with the M Sport oil cooler duct. I had to order this part from Germany because BMW currently thinks its a euro part only.

Driver side brake duct:

Now this is something you don't see very often, the driver side(left) PPK v2 radiator duct. If you don't have the radiator then this part won't apply to you. I made a couple of observations, first of all it is noticeably thinner than the other ducting made for the car. Its nearly flimsy and it also has tabs that slide in behind the metal tabs on the radiator itself. I won't be keeping this radiator for long but still found it interesting in how it mounted up as well as to figure out how to re-purpose this duct for my setrab.

Here is a better shot of the mounting tabs, there are only two screw holes, inside and outside, and I'm not sure exactly what type of fasteners it is supposed to use. I just used a spare clip nut I had laying around.

They made this a two piece design, presumably to save costs and the front portion will differ depending on which style bumper you have:

And here is what it looks like with all four ducts in place. I'm still trying to figure out how to fasten the radiator ducts, so don't mind my foot:

Another observation with this kit, is that I'll need to buy a pair of H11 bulbs as the bulbs from my old bumper are H8' and they did not come with the foglights in my kit. I bought a set of HPB H11 LED bulbs with error cancelers.

The things I bought:

PreLCI E92/3 M Sport Undertray
PreLCI E92/3 M Sport Fender Liner(Left) #51718045399
PreLCI E92/3 M Sport Fender Liner(Right) #51718045400
PreLCI E92/3 M Sport Brake Duct(Left) #51748045363
PreLCI E92/3 M Sport Brake Duct(Right) #51748045364
PreLCI E92/3 M Sport Fog Lamp Support(Right) #51118043230
PreLCI E92/3 M Sport Oil Cooler Air Duct #51748045348 (Ordered from EMIAuto in Europe)
PreLCI E92/3 M Sport Oil Cooler exhaust duct (Use the non-M Sport vent)
PreLCI E92/3 M Sport Performance Air Duct Kit #51742157670

The fog lamp support is optional, as my bumpers came with both supports, however they are closed and require cut out. So if you have an oil cooler, you'll want to either cut out a hole for air flow to the cooler or buy the part number for the right fog lamp support above. For the driver side, if you have the radiator there, you'll need to cut out the support as I cannot find a part number for it.

I did not like the driver side duct which came with the Performance Air Duct kit, it was flimsy and did not have the angled vanes to block rocks and debris. I used this: 51747260405

 

[Jeffman]

Excellent write up pictures, @Doubles!

 

[doublespaces]

I finished the install today, here are the rest of the little things I did:

Because I couldn't find anything better, I took the plastic rivets/push fasteners from my TPMS receivers and used them here:

The foglights I got did not have any hardware for fastening to the fog support, so I went to home depot and got a couple 1/2" fasteners that seem to work well. Might consider putting some loctite on them:

For securing the fog support to the bumper, pull the clip nuts from the old fog lights and use them here, there are three per foglight:

I used the cooler vent I had installed on my non-msport fender liners, they have angled vanes and its much more sturdy than the crappy, flimsy vent that came with the performance air duct kit:

 

[doublespaces]

Okay, here is a long overdue update.

I scrapped the idea of using the 335is ducts, this required deletion of the fog lights which I did not want to do and also I learned the Setrab Series 6, 16 row cooler wouldn't be sufficient either, as temps will creep at idle even with the larger 19 and 21 row cores. Now due to space constraints, there is just not a big enough core that can be placed in the fender well that can stave off the heat being generated by the transmission without some sort of airflow. This means I can stuff the biggest core that will fit and either deal with rising temps at idle or I can install fans. I would prefer to keep my transmission fluid at optimal temps all the time, and not being able to idle my car too much sounds like a pain in the ass for a street car so fans are my only option. I went out and bought a Mishimoto Small Dual pass bar and plate core, it actually fit perfectly in the space provided while retaining the brake ducts and foglights. A bracket could be made to work.

The problem is that there is limited space available, and for sufficiently large enough fans the fog-lights and possibly the headlight washers would need removed. A Spal 4" fan would probably fit but the CFM likely isn't sufficient, so a pair of 5.2" pusher fans were really the only option. This creates the clearance issues I mentioned unless I tore out the brake ducts, moved things around or other sacrifices I wasn't willing to make, so I had to start over again.

Instead of ripping everything out and throwing the perfectly good ducting and PPK radiator away, I will be re-purposing the aux coolant radiator as a second engine oil cooler instead of a transmission cooler. This way I shouldn't need to upgrade the stock oil cooler if I've got two of these working together in each fender cavity, and I can maintain my factory fit and finish and symmetry.

So in light of this, I've chose to buy a Mishimoto Large Dual Pass Bar and Plate fluid cooler and I got a bracket from @Dusty Waterfall which he makes for cooling engine oil in the same spot. For those worried about this affecting coolant temps, yes it will lower overall cooling capacity, but I already have the CSF radiator for the manual transmission which is not only an upgrade from stock radiator, but the manual transmission does not have the built in heat exchanger portion so I effectively gain some cooling capacity back. Being that this is a street car and not a racecar, this is perfectly acceptable to me.

I will be cutting out my radiator carrier a bit more to make room and will be fitting a pair of 5.2" Spal pusher fans and have a thermoswitch that will control it.

Mishimoto Large Dual Pass vs Setrab Series 6 16 row:

Also, I got my M Performance BBK in the mail today, I'll be shipping it off to @A4RingedONE8T at Fab Factory for machining shortly!

 

[Dusty Waterfall]

Okay, here is a long overdue update.

I scrapped the idea of using the 335is ducts, this required deletion of the fog lights which I did not want to do and also I learned the Setrab Series 6, 16 row cooler wouldn't be sufficient either, as temps will creep at idle even with the larger 19 and 21 row cores. Now due to space constraints, there is just not a big enough core that can be placed in the fender well that can stave off the heat being generated by the transmission without some sort of airflow. This means I can stuff the biggest core that will fit and either deal with rising temps at idle or I can install fans. I would prefer to keep my transmission fluid at optimal temps all the time, and not being able to idle my car too much sounds like a pain in the ass for a street car so fans are my only option. I went out and bought a Mishimoto Small Dual pass bar and plate core, it actually fit perfectly in the space provided while retaining the brake ducts and foglights. A bracket could be made to work.

The problem is that there is limited space available, and for sufficiently large enough fans the fog-lights and possibly the headlight washers would need removed. A Spal 4" fan would probably fit but the CFM likely isn't sufficient, so a pair of 5.2" pusher fans were really the only option. This creates the clearance issues I mentioned unless I tore out the brake ducts, moved things around or other sacrifices I wasn't willing to make, so I had to start over again.

Instead of ripping everything out and throwing the perfectly good ducting and PPK radiator away, I will be re-purposing the aux coolant radiator as a second engine oil cooler instead of a transmission cooler. This way I shouldn't need to upgrade the stock oil cooler if I've got two of these working together in each fender cavity, and I can maintain my factory fit and finish and symmetry.

So in light of this, I've chose to buy a Mishimoto Large Dual Pass Bar and Plate fluid cooler and I got a bracket from @Dusty Waterfall which he makes for cooling engine oil in the same spot. For those worried about this affecting coolant temps, yes it will lower overall cooling capacity, but I already have the CSF radiator for the manual transmission which is not only an upgrade from stock radiator, but the manual transmission does not have the built in heat exchanger portion so I effectively gain some cooling capacity back. Being that this is a street car and not a racecar, this is perfectly acceptable to me.

I will be cutting out my radiator carrier a bit more to room and will be fitting a pair of 5.2" Spal pusher fans and have a thermoswitch that will control it.

Mishimoto Large Dual Pass vs Setrab Series 6 16 row:

Also, I got my M Performance BBK in the mail today, I'll be shipping it off to @A4RingedONE8T at Fab Factory for machining shortly!

That is a sexy setup. Those upper brackets are on backwards though.

 

[Tony@VargasTurboTech]

You need a trans cooler? There is a massive trans cooler that is a direct fit in our car with a little work. I wish I had known you were doing this.

This is s a 72-row cooler, fits like a glove in E90, E92, E93 I have it on our E90 AT race car. Temps don't budge at idle. I had to use a thermostat to get it up to operating temps.
http://www.improvedracing.com/setrab-oil-coolers/setrab-72-row-series-oil-cooler-p-247.html

 

[doublespaces]

You need a trans cooler? There is a massive trans cooler that is a direct fit in our car with a little work. I wish I had known you were doing this.

This is s a 72-row cooler, fits like a glove in E90, E92, E93 I have it on our E90 AT race car. Temps do budge at idle. I had to use a thermostat to get it up to operating temps.
http://www.improvedracing.com/setrab-oil-coolers/setrab-72-row-series-oil-cooler-p-247.html

View attachment 6085View attachment 6086

I actually looked at this cooler already, it was $650 the last time I looked if I recall. Improved Racing says they are actually working on a triple pass cooler that is somewhat similar but it wouldn't be ready for a couple months. If the Mishimoto doesn't do a satisfactory job, then I'll be looking at this one next. Its a bit disappointing but not surprising to hear that even this big ass thing can't hold idle temps, autos are just hot. The other reason I went with the Mishimoto Large, is because they wouldn't give me a refund on a new in box item, only store credit. Plus I didn't have to make a bracket since Dusty made me one for cheap.

 

[Tony@VargasTurboTech]

I actually looked at this cooler already, it was $650 the last time I looked if I recall. Improved Racing says they are actually working on a triple pass cooler that is somewhat similar but it wouldn't be ready for a couple months. If the Mishimoto doesn't do a satisfactory job, then I'll be looking at this one next. Its a bit disappointing but not surprising to hear that even this big ass thing can't hold idle temps, autos are just hot. The other reason I went with the Mishimoto Large, is because they wouldn't give me a refund on a new in box item, only store credit.

I think you misunderstood, it works so well I had to put an external thermostat on it to get it up to temp, at idle it won't even warm up. It's $595, but you can get it for less if you bundle it with other things.