Although Project M3 now has a bigger and stronger motor, I figured why stop there? In the quest for more stupid power, I sent Active Autowerke back the Stage 2 TD06 20G Mitsubishi turbocharger that came with the Stage 2 kit in order for to have it rebuilt to a Stage 3 configuration. On the Stage 3 turbo, AA uses a Garrett/Mitsubishi hybrid, using the same exhaust housing and wheel of the Stage 2 but mating it to the compressor side of a Garrett T60-1 (good for 500+hp). Using the Mitsubishi exhaust side of the turbo maintains the responsiveness of the turbo and minimizes any increased lag from the larger compressor wheel-the turbo still kicks in at around 3500 rpm. However, using the 25% larger Garrett wheel allows more boost to be run in the end and gives a cleaner, smoother pull.
The fun doesn't stop there. To maximize the mid- and upper-range torque, I got a set of turbo-specific camshafts from Active Autowerke, reground factory BMW cams that have about the same duration as stock but 10.9mm of lift, improving the low-end torque of the motor and reducing the effects of turbo lag.
In order to cope with these AA Stage 3 components, I picked up a set of 11mm head studs (stock studs are 10mm) and a larger fuel pump from AA. The only thing left to have fully converted to an AA Stage 3 system is the switch to a Stage 3 intercooler offering twice the flow of my Stage 2 unit. But the custom work involved in order to fit that sucker is a little too costly for me at the moment, and I think I'm happy at a maximum boost of around 12 to 14 psi anyway. People who want over 450 rhp will most definitely need that stage 3 intercooler.
I sent all the parts to Kevin Silva of Bavarian Engine Exchange, the man behind Project M3's new motor. Since the only non-factory parts were direct replacements for the original motor components, Kevin didn't have any installation problems. The only modification needed was drilling and tapping the block and head to fit AA's 11mm studs. The new threads were reinforced with TIME-SERTS(r). Because of the thickness of the new AA studs, the cams have to be removed in order to torque down the cylinder head.
This motor is a complete replacement, and the only actual engine upgrades that will be used from my last motor are the evosport pulleys featured in Part 6 (01/02). Speaking of evosport, my faith in the company so far with Project M3 (it has installed practically everything) has led to my hiring the guys for Project M3's motor swap. evosport technician Frank Lopez had completed another motor swap involving a supercharged M3 engine just a couple of days prior to mine, so I knew he'd be warmed up. Taking out the motor took him about three quarters of the day, and he expects about another full day, maybe slightly longer, to install the new one. Stay tuned.
Bavarian Engine ExchangeBavarian's commitment is to service excellence. The Northern California-based company dedicates its resources to building quality motor and driveline components with a fast turnaround time so the customer gets the desired parts quickly. Through its Website and answering service, the company has made the task of ordering and receiving products from it a real turn-key operation for its customers, which include BMW dealerships, BMW repair shops, automotive body shops as well as private individuals.
Although the company specializes in rebuilt BMW engines, its inventory includes a number of other components, including cylinder heads, camshafts, transmissions, clutches, differentials and steering racks. All core deposits are 100% refundable regardless of the condition. Every part has a two-year, unlimited mileage warranty and, in the event of a defect, the company pays labor charges up to $500 to have the replacement motor reinstalled, plus $200 towards rental expenses-the people there really want you to have a risk-free experience with them. And for an extra 30% of the cost, you can get a lifetime warranty on the motor.