325ic Calypso Euro Conversion - Houndstooth & dbilas now, MT1 & MM 3.2 stroker coming

[bradnic]

as she sits

[bradnic]

Still sorting through the supposedly easy install instructions. I put an order in with dbilas for the loose bits that were missing, shown in their pic here


pretty sure the long hose on the right is for the ICV, and there's a vacuum fitting on the bottom of the plenum, but the hose end is too big for it. bracket on the lower right is for the dipstick. cable at the bottom extends the tps connector harness.

Here's the itb setup with OEM bits installed.


The hose arrangement and valve underneath are from the previous build and will be replaced by whatever I end up doing with the booster and carbon canister valve hoses.. The dbilas instructions tell you to remove the booster hose, but then don't tell you to put it back in lol. They do explain where to reconnect the carbon canister "pulse valve" hose. Maybe I need to keep a hose arrangement like the previous build's shown above to act as a manifold for the 3 pairs of throttle bodies? we'll see


Here's the fitting on the bottom of the plenum


The other thing is the cruise control - there's no provision for it. Seems like the cleanest way to add it is to position another cable reel on the throttle mechanism and modify the mounting bracket the cable goes through. Alternatively some sort of 2:1 cable arrangement with either the throttle or cruise cables pulling the reel. I will ask dbilas - these things have been around for more than 10 years... someone must have figured this out by now!

holding up the oem bracket - it sits flat of course and the ITB throttle cable mechanism sits vertical.
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[url=https://flic.kr/p/W9AB3S]

the fuel injector harness also needs to be routed under the center ITB or it will rub


that's why a 2nd cable spool mounted to the same armature is probably the best option.

[bradnic]

My dbilas setup came with some $500+ worth of sweet upgrades, but I can't use them until I stroke out the motor and switch to MS. So I swapped in the OEM fuel rail, injectors and TPS and put the upgraded bits aside for future use.

Not crazy about the braided lines and color anodized bits anyway - it's got to be OEM+ man!

M30 TPS (6 wire connector, clicks at WOT).


nuke fuel rail with mustang injectors


aeromotive adjustable FPR (seriously pricey bit!)


Using standard m20 injectors may limit my options short term, but that's ok. when I get MS going I'll have the mustang injectors to go with. Crazy thing is the caps off two of my injectors were gone when I pulled the manifold! they must have fallen off somehow, and been burned off. Freaked me right out. I had some extra injector rebuild parts so all's well.

As to the core dbilas bits, the AFM side of the intake boot is too large...


It's part number 13-71-1-707-767, realoem shows it's for an E34/E32 M30. Didn't think I was gonna need to swap the AFM.. Obviously I don't plan to keep it but I'm at a bit of a loss here. Don't want to just do a MAF conversion either if I'm not going to need it with the supercharger. After checking out r3v classifieds, if I can find a tune that will work with an M30 AFM I'll probably just do that.

[bradnic]

Tight fit.:up:

yeah but I really don't want to cut the heater core pipe. gonna brainstorm a bit and see what I come up with. once everything's all set I'll pull it all apart and go over everything cosmetically. can't stand rusty stud bolts on my ITBs, and have an unhealthy zinc chromate fastener fetish.

this is a 29 year old, 1987 68k mile M20. that's what I want my engine bay looking like.

[bradnic]

Thanks Rob.. almost picked up that heated seat kit you you had on eBay for my IX... then I realized I had a couple of heated seats in the attic lol.

I pinged the bimmerheads guys for advice on tuning my 'stage 1' ITB setup (just the dbilas, keep AFM or switch to MAF and reuse it later...). Don't want to plunk for $350 for a dbilas chip when I know I'm gonna do MS... Just not sure I want to go MS right away. I'd like to drive this car in the summer, not have it taken apart..

[robrez]

Big things in store! Good luck Brad.

[bradnic]

ow my wallet

just picked up an MT1 again. lots of work to do

[e30m3s54turbo]

Tight fit.:up:

[bradnic]

dbilas trial fit

official dbilas M20 install instructions - not very complete though
https://www.sendspace.com/file/xalja7

dbilas M20 installation thread from South Africa. MUST READ. Terrific, detailed. Disappointing performance outcome though.
http://www.e30clubsa.co.za/forum/ind...n-on-m20-325i/

sp33dy's 2009 dbilas posts in South Africa mentioned having to cut the heater core pipes back and grinding a bit off the thermostat housing to get everything to sit properly. Seems like I may be able to find a wrap around heater hose to avoid cutting the heater core pipe.

Initial trial fit, with the thermostat housing removed


aligning the plenum


sure enough, here's the heater core pipe issue. gonna try bending the pipe a bit rather than cutting it, as I don't have a way to put that lip back on it.



As to wiring and vacuum,
- just realized I'm missing the TPS sensor harness. Was hoping to keep a stock setup there for now. I should be able to reuse the stock one, and save the variable TPS that came with the kit for later once I adopt MS2
- need to pull the full injection harness off the stock manifold.
- had to relocate the starter/sensor harness that's routed below the stock manifold.
- no clue on the vacuum line routing right now, but I do have a valve cover hose

[bradnic]

Thanks Raul. Sat on the thing for 2 years, lots of research along the way. Gonna tackle things in phases:

this year
- stock motor straight install. expecting a torque boost below 2500-2600, and a midrange torque drop. this is based on several threads out there basically stating the dbilas plenum is too small and 45mm ITBS on a dbilas are too big for a 2.5 motor. I still want to stick to dbilas though because of its overall packaging and plans to stroke and SC.

2017 EDIT: this happened as described, though the low end torque boost if there is barely noticeable. instead with stock displacement and cams you see a nice surge above 4200 rpm or so.

still this year
- add MS (2 or 3 haven't decided, either whodwho's or build my own)
- add headers (RDs hopefully)

2017 EDIT: MS hasn't happened yet because the M30 + 19# injectors and SSSquid chip work ok :-). I do have a set of RD long tube headers, and am on the list for the 2nd batch of RD snake headers (see post 195 for pics). if they ever actually happen I'll use them on this car and either move the long tube RDs to our IX or sell them.

next year
- stroke out the motor. 2.8 or 3.1

2017 EDIT: going 3.1 for sure, but 2018 at earliest.

at some point after that
- go for the SC setup similar to whodwho's serpentine+vortech

2017 EDIT: undecided on this. I may punt after the stroker work, especially if I do a real E30 hotrod.

[e30m3s54turbo]

I will be watching on the itb install. I will be looking for your power gains. Nice kit....

[bradnic]

Thanks Barron..
Gonna try it out.. Let's see where it goes. I'll give you "dibs on the dbilas" though :-)

[411]

..........nice;)

[bradnic]

As previously installed in gforce323's 2.8 stroker

[bradnic]

taking the plunge

so much for waiting until June...



the target


business end


corrosion on center itbs, probably heat related? will need to sandblast and refinish at some point
EDIT: turns out it's just a coat of paint on the housings. gonna wire brush it off.

you can see where seller cut the exiting throttle cable off



ordered a new throttle cable and some additional hardware that didn't come with my parts
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the fuel lines, adjustable FPR and bit of vacuum line that came with the purchase. the braided hose is a bit much for me. fittings are mostly for show anyway. I'll get everything running and then de-bling.


not quite sure what to do with this yet. there's a 4 pin connector on it. pressure sensor? came with the buy but I doubt I need it.