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jturboawd jturboawd is offline
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Default M3/4 A2W Intercooler on N55 - 11-06-2017, 07:11 AM

Just a heads up. I recently completed the install of a A2W intercooler on a 2012 135i and wanted to provide some lessons learned and feedback, mainly for peers who search for this info later on. Key take aways:

1. the S55 intercooler, tank, etc all pops onto the existing N55 manifold
2. The throttle body pipe fits but does not use the retainer that the N55 comes with it. Youll need that white expander to use this, or make your own
3. You can use either TMAP location. You will need to extend the wires to get to the S55 one on the intercooler (which is what I did) then I use a stock one to block the whole int he customer charge pipe which also allows me to plug and play if I want to go from 3.5 to stock TMAP.
4. I used a 24" x 12" heat exchanger. Cut a bunch of plastic, made mounts to attached to the top 2 bolts of brackets that support upper bumper. also made mounts to mid section to plastic remaining structure. Tilted with bottom further in by 2 inches. This BARELY fit. Make sure to test fit with bumper.
5. I used a OEM bosch water pump, same common pump many OEM uses, I think its the same as the cobra. I mounted the pump in the area opposite the oil cooler. I mig'd up a aluminum mount that bolts to the front bumper rail (2) bolts. I used rubber to mount it. Attached to exchanged and OEM intercooler lines.
6. I used the OEM S55 (2) piece engine cover to make the install clean looking

The hard part:

7. You need to re-route the intake. I could have left it on the turbo side but opted to move it. I took THe F series route. I tried using a BMS F series intake but IT DOES NOT fit. It was close but its a hard no. I make my own from aluminum. I mounted the OEM sensor tangent the old one, (the wires actually fit).
8. Valve cover vent. You need to get the valve cover a vent and there is a little stupid heater in place that I opted to leave functional to avoid CELS. I used the F series inlet and vent tube and it worked like a charm.
9. You need to fab piping to go from turbo outlet to intercooler. Since I was using a EFT kit, the outlet already points up. If it was a PS2 youll need to fabricate a bend.

Parts needed:
A. 3" and 2.5" aluminum pipe kits with couplings :150
B. S55 intercooler with tank, mounts, lines, and charge pipe : 350
C. 24x12 heat exchanged: 150
D. pump : 100
E. Mig welder with spoolgun: 500
F: a bunch of lines, fittings, etc: 100

So if you have the welder already its a total of 850. the heat exchanger is larger than OEM bmw. The N55 runs lower revs and typically less power, should be plenty of cooler (especially with meth) for any N55 platform. Should also spool better, have better transient response, and much less boost loss across the core.

I will put together some pics and videos seperately after the dif and SSP clutch installs and tune. This might be some time. Wanted to make sure I dont get lazy and not post this info later.


2012 N55 135I, Speedtech 7670, JB4 + MHD, Fuel-it port injection & stage 3 LPFP, M4 A2W IC, Mfactory LSD, KW V1, Apex EC-7
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WaqasRiyami WaqasRiyami is offline
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Default 11-06-2017, 07:24 AM

Great Info
Any Pic's ?


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Default 11-06-2017, 07:39 AM

In for pics... did you do the ice tank in the trunk too?


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JETmn JETmn is offline
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Default 11-06-2017, 08:44 AM

Very cool, do you notice any differences in spool speed?
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jturboawd jturboawd is offline
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Default 11-06-2017, 09:09 AM

ill get pics up as soon as I clean her up a bit. Was a long weekend. May not have pics up for a couple of weeks. Will not know performance for a month or so. Have to install the SSP clutches, rear end, break it in, and start dialing it in. Will dyno, etc, likely in january.


2012 N55 135I, Speedtech 7670, JB4 + MHD, Fuel-it port injection & stage 3 LPFP, M4 A2W IC, Mfactory LSD, KW V1, Apex EC-7
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Default 11-06-2017, 12:00 PM

Good stuff man!


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houtan houtan is offline
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Default 11-06-2017, 03:03 PM

Great work. Looking forward to seeing what it looks like and also how the ssp install goes.
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jturboawd jturboawd is offline
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Default 11-07-2017, 05:40 PM

below are the images. Hopefully they show up







https://imgur.com/1c4JVzJ
https://imgur.com/NHti1cK
https://imgur.com/htzULYu
https://imgur.com/50dJeTq


2012 N55 135I, Speedtech 7670, JB4 + MHD, Fuel-it port injection & stage 3 LPFP, M4 A2W IC, Mfactory LSD, KW V1, Apex EC-7
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Default 11-07-2017, 07:58 PM

Quote:
Originally Posted by jturboawd
Sweet!
Lol it really resembles the s55 under the hood now, you even have the cover engine cover too.

Get us some logs to see if there's an improvement!


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jturboawd jturboawd is offline
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Default 11-07-2017, 08:02 PM

yeah the intake piping ended up looking ****ty so I wrapped it. I will re-do it post tuning. I still need to trim the upper engine cover that blocks rain from engine bay. I plan on trimming the center section out of it.

Not mentioned above but should be is how I am wiring it. I am using a 2 minute timing, switch and relay to have the pump always run after the car has been on for 2 minutes. A inline fuse goes to a tattle light to let me know if the pump fuse goes. I will also monitor IAT via JB4 to look for pump failure. Its a OEM unit though so I am hoping for good reliability. Running water + water wetter.


2012 N55 135I, Speedtech 7670, JB4 + MHD, Fuel-it port injection & stage 3 LPFP, M4 A2W IC, Mfactory LSD, KW V1, Apex EC-7
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houtan houtan is offline
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Default 11-08-2017, 08:02 AM

Nice work brother and thanks for taking the time to post and share the info. Truly impressive.

You think you will have to do any rescaling for the MAF due to the new intake?
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jturboawd jturboawd is offline
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Default 11-08-2017, 08:11 AM

I sure hope not. The car will nearly run without it. I will review logs and see. The cross sectional area at the MAF looks to be nearly the same. I think the DME uses mainly the TMAP for high load and the MAF for idle low load. Not sure if I would scale the MAF or just redo the intake pipe, for which I will have to do anyways as its not to my liking. Its very functional at the moment though.

Will hard hard to show improvement as I changed so much and not many are running the EFR. I will be able to compare EFR + A2W to PS2 + Big top though. I will log with and without meth to see the intercooler efficiency. All in all I did not go A2W because I wanted more consistent IAT or needed a higher capacity intercooler, using meth and E85 the intercooler is really just nice to have. I am mainly using it because I wanted lower pressure drop (which should be a good amount difference) and better spool/transient response due to less volume between turbo and piston. I think the EFR 7670 is likely the biggest turbo I can fit in the EFR family on my frame without going top mount, so if I can get a extra 2 psi usable boost with better response then it was worth it. I also wanted to do something different. So DCT + EFR 7670 + A2W seemed like a legit set up to run with


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Default 11-08-2017, 10:03 AM

Lookin good! If iat are still climbing when you get it all dialed in, an ice tank setup would fix that. (You wouldn’t need to ice it down, just the extra 3-5 gallons of capacity would give you al lot more IAT stability....then on race day when you ice down it would really work well )


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jturboawd jturboawd is offline
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Default 11-08-2017, 10:23 AM

the issue is the IC is SO high in the engine bay and I was always of the impression the tank should be at the highest point in the system. To get a large tank I would likely have to fab one up with aluminum to fit snugly somewhere with a neck even with the IC. I bet I could tripple the size of the OEM tank, but that would be adding a gallon at most.

Logs will tell for sure. If it was a turbo LS in a big engine bay a 3 gallon tank would be easy.


2012 N55 135I, Speedtech 7670, JB4 + MHD, Fuel-it port injection & stage 3 LPFP, M4 A2W IC, Mfactory LSD, KW V1, Apex EC-7
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bantam bantam is offline
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Default 06-08-2018, 05:56 AM

Glad to see someone else doing this, although a little sad to see that I will not be the first one.

Can you elaborate more on the wiring? I have some ideas, but this is one part that I have not really finalized for mine.

also, did you get it running? and how do you like it?
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jturboawd jturboawd is offline
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Default 06-08-2018, 07:04 AM

Wiring is pretty simple I just run a relay triggered by a timer solenoid to come on about 1m after start up. It’s been done for months and being daily driven. Iat are better. Can’t say it was worth it but I am happy with results. I think if you can diy it then it’s a worthy mod. If you have to pay a shop for fab it would not be worth it.


2012 N55 135I, Speedtech 7670, JB4 + MHD, Fuel-it port injection & stage 3 LPFP, M4 A2W IC, Mfactory LSD, KW V1, Apex EC-7
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zipphreak zipphreak is offline
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Default 06-11-2018, 06:59 AM

This is pretty awesome what you did. Retrofitting is a fun game.


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jturboawd jturboawd is offline
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Default 06-11-2018, 07:22 AM

it was easier than I thought it was going to be. If you are good at piping would be even easier. intercooler flanges right up. Can even use the s55 short charge pipe. interooler literally pops onto existing intake box nipples.

Warning though, the heat exchanger I used is big, like barely fit big, like WTF was I thinking big. So if you do this I recommend using a heat exchanged that is 2" smaller in both directions (atleast) and go as thick as you can go.


2012 N55 135I, Speedtech 7670, JB4 + MHD, Fuel-it port injection & stage 3 LPFP, M4 A2W IC, Mfactory LSD, KW V1, Apex EC-7
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jturboawd jturboawd is offline
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Default 06-11-2018, 07:26 AM



https://imgur.com/a/FDCNJjj


2012 N55 135I, Speedtech 7670, JB4 + MHD, Fuel-it port injection & stage 3 LPFP, M4 A2W IC, Mfactory LSD, KW V1, Apex EC-7
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