e36 M3 technoviolet vert, wide mitos, rms stage 2, ferrari bbk

[vwgti16vt]

On to the oil separator......

With the shop extra busy I was lucky if I got to work on the car once a month. This gave me plenty of time to research.

I decided that the OEM cyclone oil separator was so specific to plug into the side of the OBD2 intake manifold that it was a waste of time to try and use it. It would look terrible and a be a constant failure point.

Did a ton of looking around. Mann Provent 200 seemed a little overkill. My engine was low mileage, I am only running 12 psi and its size was massive. I saw that they were releasing a few smaller versions but know one in the US could get me one and the way they had to be mounted was going to cause some issues as well.

I called a few friends and got both a BSH and a 42 Draft Design catch can. My 2 problems were there size and they were more designed to be manually drained. I wanted the breather/ oil separator system to be maintenance free so both of those options were not off the table. I knew I could chop them up and make one of them work but I knew I could find something better.

As luck would have it around this time I started a large build on a customers E39 M5. The car ran 2 oil separators. Small compact simple design, an OEM design and they didn't have any check valves. My only concern was there lack of size. The factory used 2 on the 5 liter M5 engine so I wasn't sure how a single unit would would on a boosted 3.2 liter.

Regardless, I proceeded and developed this.

It uses the stock fitting on the valve cover, Pulls vacuum of the intake tube of the supercharger and drains into the dipstick tube. It was exactly what I wanted. A completely separate breather/ oil separator system with no maintenance. It was based on all proven OEM parts and fit completely hidden under the intake manifold.

[vwgti16vt]

I chose the RMS stage 2 kit because of the intercooler. It take up a lot of room so a few things had to be removed and moved to make room for it. The factory traction control, its related throttle body as well as a few brackets all needed to be removed. The original location of the power steering reservoir was also in the way.

Removing the traction control was easy. I removed the control motor and the 2nd throttle body. Followed that up by cutting off the control motors bracket. Having removed this system on the e36's before I was aware that when the traction control system did not see the presence of the controller motor it would also disable the ABS. I used an off the shelf 10 ohm resistor from radio shack as well as a few OE style connectors to trick the the traction control system into thinking the ASC motor was still in place.






The completed simulator. I made it plug n play style so I wouldn't have to cut the factory harness.


With the sim in place I was able to relate my ABS. Unfortunately the ASC light would be on in the cluster. Simple fix, just pulled the cluster and removed the ASC bulb

[vwgti16vt]

For the power steering reservoir I kept its general position the same so I wouldn't have to make any customer PS lines. I basally just dropped it down and moved it inward towards the engine.

Modified power steering reservoir bracket



The only other change I made was to mount it to the bottom side of the engine mount bracket instead of the top




Gave the PS reservoir and PS lines a quick detail and installed them in there new home
I didn't take a pic, but the rack was fully cleaned before the project was wrapped up

[vwgti16vt]

Finally time to permanently mount the supercharger. Its a Vortech V2. Decided that I didn't like the look of the stainless hardware so I replaced everything with Black grade 8 for a cleaner look.





With the supercharger in place I could now do a more precision mock up the intercooler and intake.
(sorry about the blurry pic)

[vwgti16vt]

Next on the list was intercooling system. It's comprised of 3 parts. The intercooler (between and supercharger and engine) the heat exchanger (basically a small aluminum radiator), and the electric water pump that drives the entire system.

Nothing to tricky on the actual intercooler. I wanted it easily serviceable and to look like it fit in under the engine bay. I decided I would use black AN fittings and black push lock hose for the entire system.

Wasn't sure what fittings I needed so I order them all!, haha


Installed my NPT to AN adapters and line. Left plenty extra since I wasn't sure how everything would be mounted




Unfortunately when I went to install the intercooler I found that I wasnt going to be able to get the silicone couplers in place with the supercharger installed. So out it came and the intercooler went in.



Next was in the intake tube, bypass valve and related tuning.
As you can see in the pictures the bypass hose was getting pitched by the mount for my Dinan strut car. I new it was only a matter of time before it caused issues so I later swapped for a UUC brace that I had installed on my wife's sedan

[vwgti16vt]

I made a few changes to the base version of this kit prior to installation. One of those changes was to upgrade to a porsche 803 MAF. Its pretty much plug n play other then making a tiny chnage to the ground circuit of the wiring. Since the new location of the MAF required me to extend the harness I made both changes at once. I used OEM wire and tape from BMW to, once again, keep it extra clean.

[vwgti16vt]

There was no possible way that I was going to use the heat exchanger the way I got it. The water necks were in the wrong place and I needed AN fitting. Broke out the ol' die grinder and got to work. Moved the locations of the water necks and prepped it for my TIG master best bud to do his thing.






Back from getting welded up I hit with a little semi gloss black on the end tanks




Sexy Finished Product