On3 Performance Turbo Kit Impressions on AWD 335xi + Additional Parts List

[rayrobot]

First off, I would like to thank Tony Vu for helping me score a deal on the On3Perfermance Single Turbo Kit. He helped me get a small discount off the kit. I went with the original turbo option 55mm (GT30) with plans of upgrading to a PTE 5862 in the future. The reason for this build is having a fun reliable car; I didn’t want to deal with the extra components in a twin turbo. My original twins were on the way out as the wastegate rattle was obnoxious. I paid a total of $2480.00 for the kit with all the deleted options available.

I chose the On3 kit as opposed to the DocRace kit mainly for price. The Docrace kit with a 5862 Ball bearing costed 5,095.00. They also wanted an extra $500.00 for the awd version of the kit. Not sure what the difference between the two kits are but a total of 5,595.00 wasn’t looking too good for me. I’m planning to ride out my On3 turbo until it goes and buy a 5862 later on.

Additional parts for the install:

• Tial 44mm Wastegate – 367.75
• 100pc Stainless Steel Locking Ties – 8.80 – For exhaust wrap, figured it was cheap enough to just buy a 100pc
• DEI 2”x100” Exhaust Heat Wrap – 63.35 – I know I did not need this much but it’s better to have extra.
• GT30 Turbo Oil Drain – 10.99 – Many people have claimed that the oil drain provided in the kit was no good, so I went ahead and brought this drain from ebay.
• PTP T3/T4 Turbo Blanket – 109.95 – Same vender Docrace uses
• PTP Turbo Blanket Springs – 8.70
• Reflective Heat Tape 2”x30” – 8.99 – Didn’t actually end up using these.
• ZenTuning Heat Shield – 55.00 Copied Docrace design but had free shipping on their site, so I went with them. Docrace wanted 25 dollars shipping on this part – Did not use this either because it came in contact with the turbo.
• Mac Solenoid – 62.50 – Purchased from motiv with their PNP plug wired in
• Motiv Boost Box – 172.50 – Purchased with their Black Friday Deal going on
• 5pc 1/8 NPT to ¼ Hose Barb – 8.88 – For Mac Solenoid and Boost Reference Point on Turbo
• 10ft ¼ Vacuum Hose – 6.99
• ¼ Hose Barb Tee – 5.95 – For Wastegate and Mac Solenoid Plumbing
• 20x Exhaust Short Copper Nuts – 9.80 - OE Part Number 11721437202 – Yes I know, I only need 16 but I purchased more for preventive measures.
• 4x Genuine Exhaust Nuts – 7.12 - OE Part Number 18407502196 – Purchased just in case.
• 18x Genuine Exhaust Studs – 12.60 - OE Part Number 11127593376 – 2 extra just in case.
• 6x Genuine Exhaust Manifold Gaskets – 36.00 - OE Part Number 11627558906
• Genuine Water Pipe Gasket – 15.15 - OE Part Number 11537545302
• Coolant Feed Pipe Hose (On water Pipe) – 13.59 - OE Part Number 11537558523 – Reinz - CHE0494 – Preventive Measure
• Genuine Oil Pan Bolt Set – 31.16 - OE Part Number 11132210959 – Preventive Measure
• Genuine Oil Pan Gasket – 36.40 - OE Part Number 11137548031 – Preventive Measure
• Genuine Oil Level Sensor O-Ring – 6.00 - OE Part Number 12611744292 – Purchased just in case
• 5x Turbo O-Rings – 10.00 - OE Part Number 11427558936 – 4x o-rings are for coolant plugs and 1x for the oil feed – brought new ones because why not
• 6x Screws – 11.40 - OE Part Number 07129904588 – used on the 4x Coolant plugs and 2x Oil Returns (1 oil return is obviously blocked off and the other will be the ST oil drain)
• 1x Screw – 3.85 - OE Part Number 07129904068 – used on oil feed fitting on block
• 2x Turbo O-Ring – 6.36 - OE Part Number 11427563453 – used on both oil return fittings (again, one is blocked off; one for the ST)
• Front Coolant Hose – 19.99 - Rein 11537541992 – Preventive Measure
• Heater Core Return Hose – 46.46 – OE Part Number 64216951946 – Replaced because mine didn’t look too good.
• DEI 3/8 x 3’ Fire Sleeve – 17.50 – For Oil Feed Line
• DEI 1”x3” Fire Sleeve – 34.13 – For Oil Drain – Lands right next to the wastegate
• Spectre Air Filter 3” – 21.76

Extras/Maintenance/Mods:

• N20 3.5 TMap Sensor – 67.54 - VDO 13627843531
• 335IS Motor Mounts - Warranty from FCPEuro – 22116793240 (Costed me nothing)
• Water Pump Kit – Also Warranty from FCPEuro (Costed me nothing)
• 2x Motor Mount Top Nuts – 1.78 - OE Part Number 7119904670
• 4x Motor Mount Bottom Bolts – 9.04 - OE Part Number 22116850329
• Aluminum Power Steering Pulley – 40.23 – from ebay
• 10pc Front Control Arm Kit – 600.82 - FCPEuro E90CAXDRIVE2
• 4x Control Arm Bolts – 21.76 - OE Part Number 31106797237
• 4x Control Arm Nuts – 6.60 - OE Part Number 33326760668
• 4x Front Subframe Bolts (Front and Middle) – 31.52 - OE Part Number 31106769907
• 2x Front Subframe Bolts (Rear) – 10.68 - OE Part Number 31106767497
• Oil Level Sensor Nuts (3) – 2.07 - OE Part Number 07119905544
• 2x Power Steering Rack Bolts – 12.60 - OE Part Number 32106769064
• 2x Power Steering Rack Nuts – 4.88 - OE Part Number 31356757707
• 3x Power Steering Pulley Bolts – 2.70 - OE Part Number 07119905739
• Charge Pipe O-Ring – 4.87 - OE Part Number 13717568031
• 2x Downpipe Gaskets – 27.18 - FCPEuro Reinz 18307553603
• 2x Steering Column Torx Bolts - 3.56 - OE Part Number 32306778609
• 4x Power Steering Washers – 3.60 - OE Part Number 07119906463
• 2x Power Steering Washers – 2.58 - OE Part Number 32411093596
• 2x Front Differential Inner O-Ring – 6.12 - OE Part Number 31511213527
• 2x Front Differential Axle Shaft Seal (Outer) – 33.94 - OE Part Number 33107505601
• 2x Front Differential Fill/Drain Plugs – 9.54 - OE Part Number 33117525064
• Mac Solenoid Bracket – 14.99 – from ebay
• N55 PR Coil Conversion – 159.97 (Had to relocate the N54 Coil Kit because it was too close to the turbos)
• N54 PR Coil Kit – 403.96 (included in this listed because why not)

Mods Conclusion (So Far):

• VRSF 7in Street Intercooler
• ER Charge Pipe w/ HKS BOV
• Mishimoto OCC w/ RB external PCV (Low Side)
• BMS OCC vented to Atmosphere (High Side)
• Custom Oil Cooler Setup w/ PSP Thermostat Delete Plate
• Index 12 Injectors (Coded)
• PR Ignition Coil Set (used with n55 conversion kit)
• NGK 95770 Spark Plugs at 0.022 Gap
• Euro Tuning Group Stage 3 Fuel Pump
• Motiv Boost Box (Connected to the forward connector)
• PNP Mac Solenoid
• On3 Single Turbo Kit
• 55mm GT30 On3 Turbo
• Tial MV-R 44mm WG
• N20 3.5 Bar TMap Sensor
• *Stock Clutch and Drivetrain =(

My nits and grits about the On3 Kit:

Let me just say, not every kit sent out by On3 is exactly the same in my opinion. I’ve seen and asked different people with the kit and they had different fitment than mine.

• Stated before; I’m installing this kit on a 335xi AWD. To start, it is NOT a direct fit into the 335xi. The exhaust flange on the downpipe would not line up to the OEM location catback. I had to modify my OEM exhaust. (No Biggie, I planned on keeping my OEM exhaust for this build)

​

• Both Rear O2 Sensors had to be relocated. The flimsy part of the subframe was blocking the install. I also didn’t like how the rear o2s point directly into the ground on On3’s downpipe location. My car is pretty low and I was worried they would rip right off.

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• Dump Pipe hits the passenger motor mount. Had to bend/dent to prevent rattling during idle. (Subframe did not needed to be cut like how other 335xi owners did. The dump actually extended out right in front of the flimsy part of the subframe.)

vs other On3 owners... (I do not take photo cred)​

• Downpipe sits way too CLOSE to the valve cover. I’m worried the plastic valve cover would not hold up. I can maybe fit two pieces of paper between the two. (I’ve seen another picture of an on3 kit where there is actually more bends to avoid this from happening)

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• Tial WG Exhaust Flange vs their Chinese 44mm Flange. – Pictures will do justice here. Can’t tighten the WG fully because of the flange thickness differences. I had to modify/grind the clamp so it would allow more tightening.

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• Since I’ve read other reviews about the On3’s oil drain fitting being a pita; I went ahead and ordered a GT30 oil drain from ebay. The one people have linked me towards actually. Oil Drain purchased from ebay needed to be bent at a further angle to allow a better clocking position and to also clear the v-band clamp. Closest I got the turbo clocked is near 11 and 5 o’clock. Shouldn’t be a problem but bending that drain to a more aggressive angle was a huge pita.

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• Oil Drain Hose was given a fire sleeve made by DEI since it was literally resting on my WG top hat. Not too sure how hot it gets so better safe than sorry. I went ahead and used the fire sleeve on my oil feed line as well.

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• Downpipe heat will probably melt the rubber portion of the ac line. Purchased an Aluminum Heat Sleeve and praying.

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• Spectre 3” Air filter rubs on the hood rib. (On3 is not to blame here but I thought I’d give this a mention.)

If anyone has any picture requests (I have tons of pics) or extra clarification on anything; i'd be glad to help. Just ask.

Couple extra engine bay pictures:

Thanks for reading !!


UPDATE TIME~~~!!

Time to update this thread since its been a while. I’m now running a PTE 6266 ball bearing turbo with the T51R mod. The clutch was changed to a 335is/550i clutch with a brand new stock dual mass flywheel. My power goals aren’t high and thought this combo would do well without sacrificing the stock clutch feeling.


First off, the major problem dealt with:
Sadly to say, the turbo was not a straight bolt on. I had to bring it in to a shop to get the downpipe modified.

The PTE had a bigger compressor housing. The housing touches the valve cover and forces the turbo to be angled at a different place than the smaller 55mm On3 turbo.


The turbo also comes in contact with the hood and rubs nonstop. Not much i can do about that. But be sure to buy the right oil fittings to clear the hood as well.
Had to buy an 90 degree 1/8 NPT female to male fitting to compliment the 0.035 oil restrictor i had. Otherwise the oil feed including the restrictor would be too high and contact the hood. (Don't have any pics of this yet)

You might also need a new silicone coupler from the compressor housing to the intercooler like i did in this case. I brought a straight 2.5” coupler at first but a 45 degree 2.5“ worked better instead.

After everything said and done, it was time to tune the car. I got tuned by Justin at Twisted Tuning. I only wanted pump gas 93 tune.

The car made 490 awhp and 447 tq at 19psi on a mustang dyno. Too bad I didn’t break the 500hp mark but the number would probably be higher on a dynojet. I also have alot more drivetrain lost due to the xdrive system.


For what it is and how the car drives, I'm more than satisfied.

More engine bay pics coming soon!

 

[Torgus]

No rush

I hear it fits sub par and that is from the owner of a local bmw shop who installed one just the other day. Compared to Doce Race ST top mounts he has installed on n54s.

Given the cost and the inexpensive turbo they send you it seems an acf or docrace is the better choice from everything I have read.

Be interesting to read your review.

 

[CornFedBimmer]

No rush

I hear it fits sub par and that is from the owner of a local bmw shop who installed one just the other day.

Given the cost and the inexpensive turbo they send you it seems an acf or docrace is the better choice from everything I have read.

Be interesting to read your review.

I can’t speak to the quality of their entire kit as I only ordered their manifold, but the fitment was great for me. Installed about a month ago, switched from my custom bottom mount kit

 

[rayrobot]

I can’t speak to the quality of their entire kit as I only ordered their manifold, but the fitment was great for me. Installed about a month ago, switched from my custom bottom mount kit

Manifold isn't one of my complaints either. Their manifold is actually pretty solid. But if i'd were given a chance to improve it, I would ask them to relocate the turbo position a little further away from the valve cover.

 

[Torgus]

I can’t speak to the quality of their entire kit as I only ordered their manifold, but the fitment was great for me. Installed about a month ago, switched from my custom bottom mount kit
View attachment 29606

What made you want to switch from a functioning bottom mount if you don't mind me asking?

What turbo are you running?

 

[CornFedBimmer]

I enjoy tinkering and it would have been a pain swapping out turbos compared to a top mount. Also, I switched from a Turbonetics 6162 to a GTX3582R and it wouldn't have fit unless I had a custom motor mount bracket made

 

[rayrobot]

Yep, its not a bad budget kit actually. But its not a straight forward install like everyone says. Im probably just picking out all the small things but yeah.

Thread is updated with everything now though.

 

[RuskiRacer]

I enjoy tinkering and it would have been a pain swapping out turbos compared to a top mount. Also, I switched from a Turbonetics 6162 to a GTX3582R and it wouldn't have fit unless I had a custom motor mount bracket made

You were running the spa manifold weren't you?

 

[CornFedBimmer]

You were running the spa manifold weren't you?

Yessir

 

[RuskiRacer]

Yessir

Did you like it for the time you had it and what made you wanna switch it not being twin scroll and a t3 flange?

 

[CornFedBimmer]

Did you like it for the time you had it and what made you wanna switch it not being twin scroll and a t3 flange?

Yeah it was a nice setup. My best numbers were 523 whp/ 518 wtq, but the turbo was a little laggier than I liked. That manifold places the turbine housing very close to the motor mount so I would have had to get a custom one made in order to switch to the GTX35R I’m running now

 

[JuniorB]

Great thread! It’s very detailed as it should be, with pics! It helps a lot of diyer’s willing to tackle this kit and knowing what to expect. I wanted to run this, as it looked like it may fit an e60 chassis. I was looking at the placement of the front manifold, that’s were the motor mount is, right behind the water pump hose.

 

[rayrobot]

Thanks, I made this thread because no one actually went into detail about the fitment. Everyone i've spoken to had no problems with the on3 kit but never said anything about the small little things. I hope this helped you out.

I also uploaded some more engine pics.

 

[twinturbos]

Thanks, I made this thread because no one actually went into detail about the fitment. Everyone i've spoken to had no problems with the on3 kit but never said anything about the small little things. I hope this helped you out.

I also uploaded some more engine pics.

Hey, what power steering reservoir is that ?

 

[rayrobot]

Hey, what power steering reservoir is that ?

It came with on3’s kit

 

[Leeer73]

Nice write up! I’m in the process of installing my on3 set up as we speak! I just installed the manifolds the other day, I’m going to work on it some more tomorrow. Do you mind if I ask questions here if I get stuck? Lol, I’m assuming I’m going to have some questions here very soon!

 

[rayrobot]

Nice write up! I’m in the process of installing my on3 set up as we speak! I just installed the manifolds the other day, I’m going to work on it some more tomorrow. Do you mind if I ask questions here if I get stuck? Lol, I’m assuming I’m going to have some questions here very soon!

No problem and good luck. Are you installing it on awd?

 

[Leeer73]

No problem and good luck. Are you installing it on awd?

Thanks for the reply! Mines is the rwd so not quite as challenging as yours. But with no real instructions anywhere on how to install the bad boy it makes me a little nervous

 

[rayrobot]

Thanks for the reply! Mines is the rwd so not quite as challenging as yours. But with no real instructions anywhere on how to install the bad boy it makes me a little nervous

Theres actually alot of reference videos on youtube and facebook groups. Just got to find them. But its pretty straight forward. I made this thread because i couldn’t find anybody actually making a write up for awd. The awd is def more conplicated than the rwd install. I think budget bimmers did an install on youtube. You can watch that.

 

[WOT808]

View attachment 29831

Looks clean.
I had similar Spectre filters on my stock turbos. The middle section of one of the filters came apart and lodged itself into one of my inlets.
The filter had 20k+ miles on it when it happened so maybe it was just time for it to be replaced. I'd recommend against using that filter for much longer.