DIY 335IX built motor/trans single turbo build

nyt

Sergeant
Sep 15, 2019
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2010 335xi
Slight hangup installing new pump and filter. Previous was using 5/16 bundy return, new is using 3/8, waiting now for the new connector.

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I took apart the old fuel filter, didn't seem too bad...

dirty side
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clean side
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New unit with dual 535s from pfs...
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pysical

Sergeant
Jun 16, 2017
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2009 335xi E90
Whats the outputs on the fuel pump go to? 2 of them go to a Y line that goes to normal plumbing I am guessing? If that is the case where is the 3rd one going? Straight out the passenger top hat?
 

nyt

Sergeant
Sep 15, 2019
316
1
277
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2010 335xi
Whats the outputs on the fuel pump go to? 2 of them go to a Y line that goes to normal plumbing I am guessing? If that is the case where is the 3rd one going? Straight out the passenger top hat?

one output connects to the other, then the remaining to the stock feed line
 

nyt

Sergeant
Sep 15, 2019
316
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2010 335xi
New setup incoming with an external feed and filter for one of the 295s. Got a continental filter assembly today. Much stronger hose, though it likely won't be needed this time.

Will post pics when I get it in and installed. Big thanks to Chris @ PFS for putting all the bits together for me. I don't have the time for it as I'm in the middle of a move and just need the car driving to get it 700 miles to the new place.
 
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RuskiRacer

Captain
Vendor
Jul 17, 2019
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2009 e93 335i
Dual 295s and an aftermarket filter assembly do not play nice.

View attachment 55598
Did your car die driving after you found this out? I was doing a pull today and car died after the pull didn't wanna start again brought it home has no fuel going to the injectors. Going to dig into it more tomorrow
 

nyt

Sergeant
Sep 15, 2019
316
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2010 335xi
Did your car die driving after you found this out? I was doing a pull today and car died after the pull didn't wanna start again brought it home has no fuel going to the injectors. Going to dig into it more tomorrow

Yep, died on the highway. After about a dozen pulls.

With 295s, there's a chance if one pump dies, you wont have fuel pressure. Check valves on the 285s are a bonus there....

Which filter assembly are you using?
 

nyt

Sergeant
Sep 15, 2019
316
1
277
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2010 335xi
Also, big shout out to Chris @PFS who was great at getting this setup together for me. I haven't had time to order all the fittings and filters and everything. He went above and beyond getting this together for me and rebuilding the pump after I figured out I needed to run dual output.

If you need fuel stuff, reach out to him. IMO, he's the best of the vendors out there for fuel products.

The system in place now is dual -6 feeds, one from the oem filter, and one from an additional fitting on the pump cap. They merge into a filter then it's -8 to a -6 Y splitter for hpfp and pi rail. The pi rail has a -6 return to a regulator then back to the pump. That should take care of it :0

I forgot to take a pic after tidying this up. Ah well.

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RuskiRacer

Captain
Vendor
Jul 17, 2019
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2009 e93 335i
Yep, died on the highway. After about a dozen pulls.

With 295s, there's a chance if one pump dies, you wont have fuel pressure. Check valves on the 285s are a bonus there....

Which filter assembly are you using?
Well I was using the spool performance one. That one broke on me so I think I ended up using some old venturi lines and making it work. I bet they gave out on me were fine for a good 15 pulls at like 30 psi on the stock motor. First wastegate pull on the built motor bye bye lol.
 

nyt

Sergeant
Sep 15, 2019
316
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2010 335xi
Fuel issues solved. The JB4 ST firmware was reporting the wrong values (low) so I was running too much pressure which caused one of the pumps without any venturis to misbehave, as it was essentially dead headed. I also hooked the boost/vac reference up which further dropped the pressure during low fuel demand.

I've been banging my head against a wall though for some other issues, some of which I just solved. I had bank to bank AFR differences, but that's just the single turbo msd81 fun. I disconnected the downstream sensors by pulling pins 19+20 from the small jb4 black female connector and reset the adaptations and now that's happy.

Unfortunately, I'm running into another issue where it keeps going open loop and killing bank 1. Fresh plugs and injectors. I've even swapped everything (coils, wires, plugs, high and low pressure injectors) between bank 1 and 2 and it does not follow. Really running out of ideas here :(

more logs here: https://www.spoolstreet.com/graphs/...id=67210&series=0,3,9,13,17,23,34&zoom=-1,126

Additional information

FirmwareInterfaceJB4_MAC_AddressTMAP_VLearned_IgnDWPMethTriggerModeFFMethSafeModeMethAddMethScaleMethPSIVINE85_SetupVFF_Offsetfuel_30fuel_35fuel_40fuel_45fuel_50fuel_55fuel_60fuel_65fuel_70map6_15map6_20map6_25map6_30map6_35map6_40map6_45map6_50map6_55map6_60map6_65map6_70
30/139//2JB4 Android A3560BF5B35EB8F41.9621.950037001008.03C53AA408127NONE1805050505053566064688.08.015.115.115.115.115.115.115.115.115.115.1

BoostSafetyPID GainAutoShiftRedFuel_OLFUA1st_limiter2nd_limiter3rd_limiterOptionsN20_TMAP6CylModeLastSafetyduty_15duty_20duty_25duty_30duty_35duty_40duty_45duty_50duty_55duty_60duty_65duty_70et_enabledet_n1minrpmet_n1maxrpmet_n1ramprateet_n1mingearet_n1minadvet_n1minafr
35.020950015.120.00.01_6_7_ON2500000000000000000000
 
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nyt

Sergeant
Sep 15, 2019
316
1
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2010 335xi
open loop issues were related to false knock from the forged bits and closed deck. After shitrockn54 was kind enough to define some extra tables for me, I was able to tune it out.


log-png.png


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nyt

Sergeant
Sep 15, 2019
316
1
277
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2010 335xi
So now that I've gotten past most of the fun issues and started turning it up, I've run into yet another problem. More boost is resulting in less power up top. Everything is smooth and logs are good, but 15psi of additional boost is making the same power at 6200rpm and less above. Similar happens at 6400rpm with an 8psi difference. The 24-22psi pull kept building power until I stopped the run at 7600rpm.

I'm wondering if this could be valve float as I'm running the factory valve train or if the factory exhaust with cats swapped to resonators is too restrictive. I need to disconnect the flap actuator and ensure that stays open to test during a pull, but I'm pretty sure I have it programmed correctly.

Any thoughts? There are no boost leaks. The turbo is a 6466g2 on a speedtech manifold and operating at under 35% WGDC.

Here are three 3rd gear pulls at various boost levels. You can see the higher boost definitely makes more power down low, but as revs increase, it falls down below the lower boost pulls.

3.png


Interestingly, the issue is less pronounced in 4th gear, but still very apparent.
34.png


And comparing a higher boost 4th gear pull to lower boost 3rd gear pull...
34low.png


This is the exhaust
ToUYPZS.jpg


Log from a 32psi 4th gear pull.. pretty much looks the same as all of them.

 
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nyt

Sergeant
Sep 15, 2019
316
1
277
0
Ride
2010 335xi
You can try to empty the center muffler which I did as well some time ago.
But my guess is valve float..

Any pics of what that looks like inside? What did it do to the sound when you made the change?