Twin 60mm TB on my M30

[535ise]

OK.......so i've been a lazy arse and i have had this TB for ages, but i've actually started working to fit the bloody thing !

I bought a spare manifold to go on my car whilst i work on my port matched manifold/TB so i can still use the car.

Swapping the manifold/injectors/fuel rail/TB/etc isn't straight forward on my car because the servo is to close to the manifold so you can't pull it of the head studs

So undo the master cylinder and pull it forward, glove box out and undo the servo bolts, pull the servo out the way and the rest of the job was straight forward. It took me about 3 or so hours at a fairly relaxed pace to swap all the parts over.

This is the first rough cut hole which was care fully enlarged to fit the adapter plate later on.



In side the manifold.

The inside edges of the hole i cut were chamfered/rounded off so the air doesn't have any sharp edges/angles to obstruct it's flow in side the plenum.

http://img231.imageshack.us/img231/9...090002r3nk.jpg

The mating face on the manifold i thought was fairly flat has a nice curve. So cut the long sides of the hole in the manifold so that the adapter plate only sit's on top of the manifold on the short sides and the long sides sit "in" the hole.

before..........

http://img354.imageshack.us/img354/8...090006r9ba.jpg

and after...........

http://img52.imageshack.us/img52/419...090011r9ae.jpg

This is the face of the adapter plate that is in side the plenum, so the air doesn't have to go around a nasty 90 degree edge as it enters the plenum i rounded the edge's of the two holes with a file.

One down one to go, oh i had so much fun with the file

http://img198.imageshack.us/img198/8...090007r8hv.jpg

Off to the engineering shop who can TIG weld cast alloy.

Original TB hole blanked of

http://img61.imageshack.us/img61/809...090015r0xh.jpg

Adapter plate welded on and new TB bolted on, they look like nice tidy welds that should be air tight once painted(incase theres any tiny pin holes

http://img78.imageshack.us/img78/285...090016r3ko.jpg

They also drilled a hole in this spare piece of 20mm alloy for me because i didn't have a big enough drill bit. This piece of alloy is going to house the TPS adapter the Alex kindly made for me as the Ford TB has a flat blade type TPS spindle and i need the normal "D" TPS spindle.

http://img52.imageshack.us/img52/908...090020r3bo.jpg

Things to do.........

Do HG job
Save for a lap top so i can change the fueling on my ECU
Make a gasket for the TB
Cross my fingers that i can use my old throttle cable and make a new bracket
fit M30 air box and cross my fingers that the E46 M3 intake elows/elbow that Ian is kindly giving me will fit both the TB and the air box
paint manifold with black wrinkle paint like my rocker cover and re-fit

What do you think ?

[BigKriss]

It loos awesome and great pictures there. Good luck with it and keep us updated. Why did you think the throttle body was a limiting factor on the car anyway?

[535ise]

It loos awesome and great pictures there. Good luck with it and keep us updated. Why did you think the throttle body was a limiting factor on the car anyway?

I think my engine can breathe a bit more as it doesn't have an AFM,the head/inlet manifold have been ported and i have a schrick cam so i thought a bigger TB might help it suck in some more air to help release some extra BHP at the top end of the rev range.

I am also thinking of putting a turbo on it at some point so having the TB that side of the manifold will help the pipe routing around the engine bay, i haven't got a lot of room for big pipes in the E30 engine bay.

[BigKriss]

Good stuff. I really liked how you have put the throttle body on the other side of the intake manfold.

[Rob]

Looking good. AsBigKriss stated, keep us updated. looks like a lot of work has gone into it. Nice photos, I expect more on them! lol.

[genphreak]

I think my engine can breathe a bit more as it doesn't have an AFM,the head/inlet manifold have been ported and i have a schrick cam so i thought a bigger TB might help it suck in some more air to help release some extra BHP at the top end of the rev range.

I am also thinking of putting a turbo on it at some point so having the TB that side of the manifold will help the pipe routing around the engine bay, i haven't got a lot of room for big pipes in the E30 engine bay.

Me too (one day)! Love the work you've put in shoe-horning that M30 into the 3, but that TB is a really hot mod. It will fly. I would like to do something similiar, even if all I achieve is to get the air coming on the cool side of the motor, but like you I plan for a turbo so a larger TB would be the go. Does it make any difference if one uses a manifold off a smaller M30 (ie 728/733/528/533 style) or should one mod the M30B35 manifold?

Any plans to delete the Motronic when you do this? Have you thought about how to route the intercooler piping yet? Space is soo damn tight in there.

One question about the TB mod you've done; I think I would have wanted to weld a thinner plate (the TB mount plate) instead, it sits quite proud of the original manifold face. It is bad enough in an e34 trying to get the intake air piping to go round the shock tower when setting up an Alpina M88-esque intake manifold, and your TB is hardly low profile- let alone the car actually any wider...

Also, are you still planning on using the FoMoCo MAF- or a MAP sensor?

Cheers, Nick

[bahnstormer]

what ECU are you using? i read ur page but didnt see what engine management u've chosen...only that u've no more AFM, and that u can
tune by computer. first guess, megasquirt? MAP sensor?

[535ise]

Nice photos, I expect more on them! lol.

It's going to be slow progress unfortunately as i'm low on funds at the mo , i have got the following to fork out for,

Parts for a head gasket on the M30(this week end touch wood)
car insurance(paid)
road tax(end of the month)
alarm/imobilizer(some time soon)

[535ise]

Me too (one day)! Love the work you've put in shoe-horning that M30 into the 3, but that TB is a really hot mod. It will fly. I would like to do something similiar, even if all I achieve is to get the air coming on the cool side of the motor, but like you I plan for a turbo so a larger TB would be the go. Does it make any difference if one uses a manifold off a smaller M30 (ie 728/733/528/533 style) or should one mod the M30B35 manifold?

I'm not to sure about the earlier manifolds but the E34/2 and E28/4 have a fairly big flat face to mount the TB on to i think ?

Any plans to delete the Motronic when you do this? Have you thought about how to route the intercooler piping yet? Space is soo damn tight in there.

The motronic is long gone, i use an Emerald stand alone ECU now which uses a TPS as it's main load input.

http://emeraldm3d.com/

I've got some general ideas about the piping but it's not going to be happening till next year hope fully.

One question about the TB mod you've done; I think I would have wanted to weld a thinner plate (the TB mount plate) instead, it sits quite proud of the original manifold face. It is bad enough in an e34 trying to get the intake air piping to go round the shock tower when setting up an Alpina M88-esque intake manifold, and your TB is hardly low profile- let alone the car actually any wider...

The plate had to be that thick to space the TB away from the manifold so the throttle mech' didn't catch, i could have gone thinner with the plate but then i'd have had to move the TB up wards which might have put it too close to the bonnet.