Monthly Archives: May 2015

Upgrade Work

Oil Lines, Finally

After a long battle with these oil lines, approximately 6 hours to get my turbo’s back in with them on, they are connected and the wastegate lines have been attached as well.

oil_lines-d

The lines to the N75 don’t yet have the adapter in place for my pressure sensor.oil_lines-bAttaching the oil supply lines to the oil distribution block was the biggest pita of the project, specifically the driver side line.  The line on the driver side is just long enough to reach, but with the thickness of the stainless steel line, heat shielding, and running it adjacent to the coolant line it was a long effort to get the fitting at the oil distribution block hooked up.

Oil distribution block
Oil distribution block

Eventually I loosened the banjo bolt fitting on the oil distribution block to the point that the fitting was almost ready to fall out.  Then I was able to maneuver the line and get the the AN fitting to thread and tighten everything up.

oil_lines_odb

 

Shown below is how the lines are attached to the driver side turbo.

oil_lines-eHere are a few additional photos of the oil and wastegate lines after getting them installed.

oil_lines-cwg_lines-aoil_lines-a

 

Flow Tests

BMW 335i N54 Inlet Pipe Test

Something different from what I’m normally testing, a BMW part.  Inlet pipes for the BMW E92 335i N54 3.0L engine.

BMW E92 335i N54 3.0L Inlet Pipe
Pipe 1
BMW E92 335i N54 3.0L Inlet Pipe
Pipe 2

The results:

BMW Inlet Pipe Airflow E92 335i N54 3.0L
BMW Inlet Pipe Airflow

For those wondering, at 28″ the higher flowing pipe has approximately 44% more CFM passing through it for the same pressure drop.  A good example of how subtle design differences can greatly affect airflow.

Some additional photos comparing the two pipes and their shapes.

bmw_pipes-e

bmw_pipes-a bmw_pipes-c bmw_pipes-d

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Adding a chart with extrapolated pressure drop information out to 350 CFM based off a least squares fit to the measured system data.

BMW N54 engine inlet airflowAnd some additional airflow testing of a pair of aftermarket options, one from MMP and the other VTT.

 

Flow Tests, Testing

K03 Turbine Flow

After soaking the turbine to downpipe studs in penetrating oil overnight I was able to remove them from the turbine housing so I could mount the K03 turbocharger on the flowbench.

BorgWarner K03 on Flowbench
BorgWarner K03 on Flowbench

I then went through the same process as I had done with the BW K04 turbocharger, recording the pressure drop through the turbine housing with the rotors fixed.

The composite results of the tests conducted thus far are shown below:

k03_vs_k04_closed_flow

Not surprisingly the K03 hotside flows less air than the K04’s at the same depression.

K03 and K04 on flowbench
K03 (L) and K04 (R) on flowbench

Next up I will be checking the airflow through the K03 housing with the wastegate door open, like what was done with the K04’s.