330D intercooler on a pre facelift 120D ?

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Manufactured from 2004 to 2011

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simyo
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330D intercooler on a pre facelift 120D ?

Post by simyo » Thu Feb 01, 2018 3:40 pm

Hi guys !

I tried to find a topic with the search button but could not find any information regarding that a 330D would fit pre facelift 120D.
The diameter of the IC hose connections are 70mm, my hoses are 63mm, so that won't fit.
I came up with an idea to use bayonet hose couplers.
I saw that forge sells them but I don't have a clue if it will fit because they are universal couplers.

https://www.forgemotorsport.co.uk/Alloy ... --600.html

Type C is a coupler (68.3mm towards 63.5 mm) which should probably fit the IC and my hose when I cut the connections off and clamp it.
Can this be done? Or does the car don't have enough space to fit the 330D intercooler?

It is actually for a small project on my car:

- Stage 1 turbo: high flow compressor wheel (11 blade billet), it is slightly larger than the standard compressor wheel and the housing is modified to the
compressor wheel, it comes also with 360° thrust bearings.
- BMW 330D injectors (0445110216 Bosch)

I am aiming between 220-240 hp.

Image

Kind regards from Holland,

Simba

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marco_polo
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Re: 330D intercooler on a pre facelift 120D ?

Post by marco_polo » Thu Feb 01, 2018 4:09 pm

I think you would be the first person to try this. Most people fit one of these on a PreFL 120d : https://www.hg-motorsport.de/shop/produ ... eries.html
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simyo
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Re: 330D intercooler on a pre facelift 120D ?

Post by simyo » Fri Feb 02, 2018 8:34 am

That one i saw too, but that's a bit to expensive.
I will give it a shot :D

Chemtails
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Re: 330D intercooler on a pre facelift 120D ?

Post by Chemtails » Mon Mar 12, 2018 7:16 pm

Keep us updated!
e87 120d 2004, camber plates and a dent

simyo
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Re: 330D intercooler on a pre facelift 120D ?

Post by simyo » Fri Apr 06, 2018 1:44 pm

Still didn't find some time to do it :(

simyo
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Re: 330D intercooler on a pre facelift 120D ?

Post by simyo » Wed May 09, 2018 11:20 am

Last week I ordered bayonet hose couplers with diameter 68 mm to 54 mm.
I also had a spare hose from turbo to IC.
I cutted of the fast coupling side of the turbohose which goes into the IC and put the bayonet hose coupler on it.
With some grease I put the hose on the coupler and clamp it with a hose clamp, so that part works !

I am still waiting for the IC to arrive so I can try if the bayonet coupler should fit the IC.
I ordered a 335i IC instead of a 325D/330D IC.
The 335i is a bit larger so I am curious if it fits. Otherwise I will return the IC and order a 325D/330D IC.

Keep you posted!

simyo
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Re: 330D intercooler on a pre facelift 120D ?

Post by simyo » Sun May 20, 2018 11:07 am

335 IC is delivered!
Good news: the bayonet hose couplers fit the IC perfectly with the OEM gaskets.
But I ordered aftermarket seals which are a bit thicker than the OEM ones, so there will be no boostleaks or what so ever :)
I did this also on my previous car, fitted aftermarket seals and it worked perfectly!
The turbo spooled a bit quicker and the throttle response was a bit faster.

So for the next part is, when the seals arrive I can finally put the IC on the car...if it fits ahaha :lol:

simyo
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Re: 330D intercooler on a pre facelift 120D ?

Post by simyo » Sun Jun 03, 2018 9:08 pm

Unfortunately the pipeconnectors on the IC are a bit to big to fit through the holes where to boostpipes come out.
Did trim a bit of the plastic away underneath the bumper to create more space because the IC is a bit thicker.
But when I fit one side through the hole, the other side gets blocked by the front axle support.

I think there is one other way and that is to remove the front bumper and remove the air duct so I can slide the IC in instead of trying to fit the IC from underneath.

But can someone help me how to remove the bumper and the main air duct?

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