1998 e36 1.9 Z3 - M44 supercharging thread

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  1. 1998 e36 1.9 Z3 - M44 supercharging thread 
    #1
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    markrnorton's Car Details
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    Z3 1.9i M44 Supercharger installation (DASC kit)

    I thought, seeing as there has been a lot of threads on supercharging lately, I’d do a quick write up on what I have completed over the past year. I’ll do this over a couple of posts as I’m bound to forget things along the way !

    Basic kit was the Downing Atlanta kit, from the States. It uses a an Eaton MP62 supercharger on a custom cast inlet manifold. Running, in standard trim, 7.5psi. Fuel enrichment is via a rising rate fuel pressure regulator, crude, but it works. It does have some adjustment too.

    This is the kit, around £3k imported with duty and courier.



    Ok, so this is the engine before we dismantle.



    The manual makes dismantling sound quick and easy, it is to a certain degree, but still requires some thought.

    Upper inlet removed, straighforward so far.



    Tricky bit here is to cut the plastic boxing out around the cabling then disconnect most of the electrical connections and thread through the lower inlet manifold.



    Ok, Inlet manifold off here, looks worse than it is here.



    Supercharger assembly


    and then assembled with inlet bend



    Mounting the idler gears next to the alternator



    Then mounting the charger in the engine block



    and with belts connected

    Z3
     
     

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    #2
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    steve23002's Car Details
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    Awsome thread.
    What sort of power upgrade doe it give you?
     
     

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    #3
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    J.Salmon's Car Details
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    nice work mate, what sort of gains has this given you?
     
     

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    #4
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    I didnt want to put back all the plastic shrowds or the viscous fan.
    The viscous fan sucks a little power from the engine so i went the electrica fan route, with a thermostat cut into the top hose , thus



    I also didnt want to use the original air box either, wanted to go for a free flow unit.
    I managed to get a simota filter originally from a 330i, so it needed a couple of silicone couplers but i managed to fit it with a bit of trimming

    Z3
     
     

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    #5
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    sorry about some of the pictures, some are camera and some are phone.

    this was how it finished mid last year

    Z3
     
     

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    #6
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    Kevin Whittaker's Car Details
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    Looks like a fantastic project... Looking forward to reading and seeing more
     
     

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    Brilliant and straightforward! How long did that take you to fit all together?
     
     

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    noticed adjustable strut tops in there aswell mate
    looks awesome!!
    still going strong? had any problems?
     
     

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    #9
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    Engine still going strong. Never misses a beat.

    The initial strip down and build took about 12-15 hours, did it over 2 days.

    There were/are however further considerations i found along the way.

    1. Brakes - upgraded these prior to install, went for vented, drilled and grooved discs with greenstuff pads (up front). With the extra power there was no way the original solid disks would have coped.

    2. Suspension - This also was upgraded prior to s/c install. Z3 suspension is ok to start with, but as i wanted to do more track days i thought best to overhall what was there. Basic changes were..... AP coilovers, polybushed, new wishbones, new droplinks, adjustable r/j billet top mounts, strutbrace and a tweek to the rear arb.

    3a. Cooling - with the s/c fitted the engine makes alot more heat. I have fitted a new radiator, thermostat housing and thoroughly flushed the system.

    3b. Cooling - Exhaust temps, these shot up !! i have rebuilt the exhaust system. i will come onto this

    4. Clutch - original clutch was only there for the 140bhp the cad made from new. once the s/c went on it slipped like nobodys business. it had to be replaced
    Z3
     
     

  15.  
    #10
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    Ok, clutch replacement

    this is the old m44 dual mass flywheel, heavy , bulky and doesn't handle power made by the s/c


    doing some research it appeared that the single mass flywheel from a 318is may be a contender along with an uprated clutch.
    i managed to get hold of the single mass flywheel from an 318is. then i had another brainwave

    I measured an M3 3.0 E36 flywheel, ringgear was the same diameter and it had an 8 bolt fixing, same as the M44.

    So, bought an M3 chromoly lightened flywheel, this saved 7kgs over the original dual mass. RESULT



    then this, coupled with an M3 clutch and cover, which is significantly larger. Splines on the M3 clutch match the 1.9 getrag gearbox input shaft too.



    and then fitted to engine


    With the gearbox back on, the clutch cover still cleared the bellhousing and original clutch actuator arm is also compatible, just replaced the release bearing for a new one.
    Z3
     
     

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