S55 intercooler setup on an E90 N55

[9krpmrx8]

And don't mind the dirt, I will get the engine bay cleaned up and the y pipe powdercoated, etc. Only pain is removing the cabin filter to check the coolant level but I don't want the BMS cabin filters so this will do until I get the balls to buy the M3 cowl setup.

 

[9krpmrx8]

This was test fitting the 3d printed Fog'r pieces to ensure it would fit and I have a proper offset couple to address the different angle.

 

[9krpmrx8]

Oh and the filter I used and some other random stuff, some of the plumbing has changed and I ditched the PWM controller, just running the pump straight off a relay as netted the best results.

 

[houtan]

Woah! Nice job brother. Looking forward to seeing logs as you fine tune.

Quick question, for the pcv connection on the valve cover side, how did you mount the threads for the AN fitting?

 

[9krpmrx8]

Woah! Nice job brother. Looking forward to seeing logs as you fine tune.

Quick question, for the pcv connection on the valve cover side, how did you mount the threads for the AN fitting?

It's a push in fitting for the N54 sold by Vader Solutions. I am kind of pissed that pic on the site is black and it came silver but I didn't have to return it, etc.

 

[9krpmrx8]

I think one of the fittings in this kit will work as well, may try it for cool points. https://www.counterspacegarage.com/radium-oem-pcv-10an-male-fittings

 

[9krpmrx8]

This is the one I got. Again, didn't come in black.

E36 E46 E9X E8X E6X Valve Cover Breather Fitting

NO MODIFICATION NEEDED, this plugs right into the valve cover and uses two o-rings that are provided for perfect tight fitment Flapper Delete Fitting for N54 WILL NOT WORK WITH RALLYROAD FUEL RAIL THAT HAS A RETURN FUEL SYSTEM AS SHOWN IN PIC (NOT THE PURPLE FITTINGS) also known as the...

vadersolutions.com

 

[CalvinNismo]

Awesome job @9krpmrx8! Does the setup feel any different to an air to air setup? More responsive? Less responsive? Indifferent? I guess the overall plumbing length is a good chunk shorter.

I too have been eyeing up the Radium fittings for a while. My Mishimoto hoses have started forming surface cracks, so I might have to bite the bullet and buy the Radium adapter.

Good job on the crank case vent setup, looks neat. How is your inlet held into the turbo? It looks like you’ve lopped the bracket off, no?

 

[9krpmrx8]

Awesome job @9krpmrx8! Does the setup feel any different to an air to air setup? More responsive? Less responsive? Indifferent? I guess the overall plumbing length is a good chunk shorter.

I too have been eyeing up the Radium fittings for a while. My Mishimoto hoses have started forming surface cracks, so I might have to bite the bullet and buy the Radium adapter.

Good job on the crank case vent setup, looks neat. How is your inlet held into the turbo? It looks like you’ve lopped the bracket off, no?

It feels more responsive and you hear the turbo more for sure. Changing the intake setup totally screwed up the fuel trims, etc. so I can't boost more than 6-7psi without it going way too lean for my liking so I am getting revisions now. I also found some leaks when smoke testing the aluminum valve cover so I had to reseal part of it with grey RTV. But I did take it apart to paint it and change the hardware so that is probably on me.

 

[houtan]

You have any logs you can post?

 

[9krpmrx8]

You have any logs you can post?

Not yet, once I get the tuned dialed in for the intake I will share, right now my STFT% sits a 33%, lol.

 

[houtan]

Ok cool. I was just curious but I get it. When I tested the 3d printed hot side intake my logs looked the same as with the injen intake so I felt pretty good about working towards the hot side intake project. Now I’m not as confident haha.

But, maybe your new intercooler setup has something to do with it as well.

 

[9krpmrx8]

Ok cool. I was just curious but I get it. When I tested the 3d printed hot side intake my logs looked the same as with the injen intake so I felt pretty good about working towards the hot side intake project. Now I’m not as confident haha.

But, maybe your new intercooler setup has something to do with it as well.

Yeah I used the Injen MAF section hoping that nothing would change but I am going to play with the orientation, the length etc between revisions to see if there is anything I can do.

 

[9krpmrx8]

So the aluminum valve cover didn't work out, the flapper in the pcv port pipe doesn't work so it was causing a constant vacuum on the PCV hose. So if you take apart the mitzone to paint, etc, I recommend bench testing it before putting it back on. When I remove that piece the door works freely but when on the VC it doesn't so something is jamming it up. I just installed a new OE one and then my water pump decided to die but I should have it buttoned up this weekend and I can get some real data.

 

[houtan]

Quick question. Do you have a link to the filter you are using?

 

[9krpmrx8]

Quick question. Do you have a link to the filter you are using?

K&N

RF-1031​

 

[houtan]

Thank you!

Sorry, I’m full of questions this morning lol. So I don’t think that filter will work for me either. I just finished installing the aluminum expansion tank from Turner and the injen intake puts the filter too far forward.

But I believe I can cut off the final bend at the end of the intake, and the filter should work. So my question is, when you cut your intake, it looks like you cut off the bend, is the diameter of the pipe still 3.5 inches? Second question, what did you use to cut the Intake? I was thinking of using my angle grinder with a cut off wheel, but not sure if that’s excessive ha ha.

 

[9krpmrx8]

Thank you!

Sorry, I’m full of questions this morning lol. So I don’t think that filter will work for me either. I just finished installing the aluminum expansion tank from Turner and the injen intake puts the filter too far forward.

But I believe I can cut off the final bend at the end of the intake, and the filter should work. So my question is, when you cut your intake, it looks like you cut off the bend, is the diameter of the pipe still 3.5 inches? Second question, what did you use to cut the Intake? I was thinking of using my angle grinder with a cut off wheel, but not sure if that’s excessive ha ha.

It's not quite 3.5" but it tightens up just fine.

 

[9krpmrx8]

Oh and the Midnightmotorsports Fog'r setup fits with the S55 manifold. But because the Fog'r pushes the TB out, I had to use an HPS HTSOC-350-BLK offset coupler.

 

[houtan]

Thanks again for verifying cutting the intake will still work with the filter. I joined the injen intake chop club. Had to do it to work with the turner aluminum expansion tank. Honestly, I wish I cut the intake when I first got it, the last bend is unnecessary imo. Logs look the same as well.

Next in the list is to make a hot side intake and 3d print it.