Rjudgey wrote:What year is your 120d? If it's a 2004 then you most likely will have a Garret vacuum operated turbo then yes you can bolt on a Alpina D3 turbo for more boost. If your in the same boat as Geeto and myself and have a newer car from 2005 with mitsubishi turbo then you can't get a hybrid, the turbo can give more boost but Stan thinks the spool would become quickly warped and ruin itself and destroy the turbo and possibly engine.
If your after 210-220 you'll need quite an aggressive boost on your map so you'll have to run a few mods to make sure nothing melts, as for gearbox that's fine just change oil for decent stuff every 30k miles, engine that's fine too Alpina D3's run 200bhp std and can go to 270bhp mapped from Stan and haven't had any major failures that he is aware about, main thing with engine is that it's relatively low miles and change oil every 7-10k miles, if it's high mileage e.g. over 100k or more then you'll need to modify the breather for the PCV system to reduce back pressure inside the engine, otherwise you'll risk the turbo blowing it's oil seal and the engine will destroy itself on it's own engine oil running out of control which trust me isn't a pleasant experience! ( I know so!) if the engines done 150k or more don't even think about this unless you plan on swapping in new engine real soon.
Clutch and flywheel will be fine if it's done lowish miles if not then replace with new items or uprate with Sachs kit not cheap but you won't have to replace it for a long time! Rest of the drive train is fine axles, prop and diff, although diff oil should be changed every 30k same as gear oil.
BMWP intercooler won't fit unless you run modified charge pipe from the turbo end so you'll have to cut and shunt both the old one and a new 120d one to fit or go with a HG motorsport Intercooler as they're your side of the Channel any fitment issues would be easier to deal with hopefully mine was just a one off and they're fitment issues are sorted out, it can be gotten around though and the actual intercooler is a very good design and well made it's just the hose connectors they had made were crap about .5mm machined too much on the inside which creates poor fit and air leak.
You'll have to get the Exhaust side sorted out 2.5" mandrel bent piping with a couple of sports silencers small ones should suffice, and then one of Stan's Decat pipes to reduce the heat from the turbo. One other thing have your EGR removed from the map this will stop it from clogging up the intake and inlet ports, you can also remove the swirl flaps Geeto has done this and could be accounting for his slightly higher bhp figure to mine, also you could remove the EGR valve and replace with a new intake without the valve this increases air flow in but to be honest probably only makes a few bhp increase at best. With a DMS map my car made 210bhp and 300lbft torque with everything std but did have tendency to chew up early turbos later revisions seemed to last a little longer boost was set at a reasonably high 1.8bar.
Other than that Stan can send you the map on his Iflash units he has a few you can swap between enviro map is very good gets my car around 190bhp and 310lbft and around 55mpg avg sometimes higher in summer. His maxitune map is around 215bhp and 335lbft which is probably the one you'll be wanting and the ecotune map sits in the middle of these two if you look at my dyno sheet posted up here you'll see the differences. Geeto was lucky enough to get mapped by Stan directly which has resulted in some impressive HP gains so if you really want that extra 5-10bhp you'll have to make a trip to Scotland if not and if your engine is in good shape (mine had 25k miles), then you should get similar figures to mine.
Thanks for your comments, it is really appreciated
My car is a BMW 120d automatic produced in late 2004 but is a 2005 model. I think it is from 11 month 2004.
Would this have the Garret turbo, and would the D3 turbo from Alpina fit to the engine? What pipe work is to be used if I decide to go that route? Do I need to find one from a 330d and will they fit to my car? I have a friend who might have a 330d IC´er from an E91, would that fit? Just to clarify my car is a M-tech version with the cool front and rear bumper
but also I have heard that this bumper is very close to the car and therefore not giving that much space for a new IC´er.
Regarding the gearbox, I am not sure you realize that I am driving an Automatic as this does not have the mentioned Clutch. I have looked at the original performance kit from BMW and here they upgrade the torque converter, due to the extra Nm. Is this necessary and can you get one from a 330d and use this instead?
As it is a 2005 model it is not running any particle filter so there should not be any problems getting read of the exaust gasses.
The Alpina kit would be perfect, it is a proven system that is not in any way pushing the engine to hard I would assume so this would probably be a good start, the only problem is to find the turbo etc. As I could read on the internet it seemed that the Alpina D3 was running a larger 325d turbo and also IC´er, can any confirm this, because the 325d is not running a hybrid turbo. I have also read that Alpina used the 535d fuel system.
I would love to have 250 hp and a lot of torque but it is my daily driver, so reliability is the keyword, but still even though it is my daily driver I would love to be able to have some fun in it while I am driving.
The car has done 200.000km which is approximately 125.000 miles, but the car is well maintained (full history) and only run highway miles so I am not so unsure about the engine. Can you please tell me a little about the need to modify the breather for the PCV system. I am totally lost here and do not know what that is?
I do not think I would change the exhaust as I am not looking for a too noisy system (again daily driver) but I have ordered a BMW performance exhaust as it would look quite nice to the rear bumper/ Diffusor.