Turbo E85 Roadster Build- Bottom Mount w/ AC

[vbelsky]

Hi, all. Sharing my '03 Z4 3.0i bottom-mount turbo build.

Brief overview:

-MS43 ECU
-Has air conditioning
-CX racing GT35R turbo
-E83 X3 2.0d Luk clutch disc, N62 Luk pressure plate, stock Luk DMF
-M50 intake manifold and fuel rail (return is welded up)
-Bosch 0280158123 630cc injectors
-B6 Audi S4 MAF sensor
-Precision turbo PW46 46mm wastegate
-EMUSA Intercooler 25in. (total length; core length is 18in.) x 12 x 3 (2.75in. core)

Turbo Specs (CX racing GT35R journal bearing)

• Compressor housing - .70 A/R
• Turbine housing - .63 A/R
• Compressor Wheel 61.3 /82 mm
• Turbine Wheel 62 /67.8 mm
• 4in. inlet and 2.5in outlet

[youtube]FLfUtnFQEuw[/youtube]

Link to my wheelwell page with tons more photos and info:
https://wheelwell.com/vlad-belsky/2rj3/2003-bmw-z4

 

[vbelsky]

List of items purchased and costs for the build

Turbo Oil/Coolant feed
• Rally Road Feed line (bottom mount)- $33
• Rally Road Vanos bolt adapter to AN4 line- $33
• M14x1.5 to 3/8 barb (coolant to block)- $9
• 1/8 npt to 3/8 barb (coolant to lower rad hose)- $5
• 36 mm coupler with 1/8npt hole- $10
• Drain line (5/8 in pushlock hose and 3/4in heat shielding)- $20
• 5/8in weld-on aluminum bung for oil drain- $5
• Oil pan baffle kit and oil pan gasket- $204
• 10ft 3/8in ID ss braided teflon line- $40

Clutch
• E83 X3 2.0d Luk clutch disc (part # 21207553770)
E60 550i pressure plate (from Luk kit with BMW part # 21207573789) - $340
• Clutch alignment tool - $8
• Pivot pin brass - $18
• OE Luk flywheel (part # 21207533868) - $370
• New flywheel bolts (part # 11227519572) - $46

Intercooler
• 2.5in Pipe kit $72
• Intercooler $80
• Intercooler mounting materials - $20
• Extra 2.5in 90 elbow - $9

Fuel System
• Bosch 0280158123 630cc injectors - $250
• Injector spacers - $40
• Used B6 Audi S4 Bosch 1800kg/hr MAF - $35
• Deatschworks DW200 255lph fuel pump- $86

Exhaust
• Manifold ($140 including labor to machine it)
• VHT 2000F paint- $20
• Dump tube and downpipe starter fab + material - $140
• T304 stainless 3in V band clamps/flanges x 3 - $54
• 8FT 304 stainless 3in pipe - $60

Turbo
• Turbo - $300
• Rally road E46 turbo engine mount arm w FEBI 15786/274111 engine mount -$180
• Precision Turbo PW46 46mm Wastegate - $350
• TiAL-style (Tial BV50 replica) 50mm Blow Off Valve - $54
•-11lb spring for BOV - $15
•Genuine Tial O ring for BOV - $5

Air Intake for Turbo
• 4 in to 2.5 in 45 degree elbow/coupler - $10
• 2.5in inlet cone filter - $14

Gaskets/Misc
• Exhaust manifold gaskets (BMW part #11621728984)- $18
• Copper spray Permatex 80697 - $10
• M7 exhaust nuts part #11721437202- $10
• Engine/trans mounts - $45
• Spark plugs NGK BKR7E (set of 6) - $18

AEM Failsafe 30-4900 wideband/boost gauge- $300

Fabrication costs
• Oil pan modification labor- $100
• Fabrication labor for exhaust, charge piping, and air intake- $650

Total:
$4226 USD

 

[Commando_Rob]

Wow awesome build what power do you think it will make once complete?

 

[LittleZ4]

Will be interesting to see the outcome of this.

 

[bearded_ed]

This looks amazing!!

 

[Machine monkey]

Love the baffle plate as you know. Nowt wrong with these Chinese turbos a lot of people making a lot of power with them

Great building hope you get yours built! A lot quicker than mine!!

 

[Ewazix]

Impressive start, good luck with the build

 

[ph001]

Sweet. What solution for the mapping?

 

[vbelsky]

Wow awesome build what power do you think it will make once complete?

I'm gonna aim for 350whp to start and work my way up from there

Sweet. What solution for the mapping?

It's running on a factory E46 3 series ECU (Siemens MS43) tuned by me, with a modified engine harness from an E46 3 series . Had to add the coolant outlet temperature sensor wiring and ac compressor trigger wiring, as those are wired differently in the 3 series of the same vintage.

 

[Mr Tidy]

That looks like a great project.

I'll be looking out for the updates.

 

[Ladderman]

Love these type of MODS. Hope the build runs smooth, please keep the updates coming with loads of photos

 

[GuidoK]

Nice build.
Are you able to run the exhaust&intake piping without cutting up the aluminium chassis reinforcement plate (on the underside of the engine)?

 

[vbelsky]

Nice build.
Are you able to run the exhaust&intake piping without cutting up the aluminium chassis reinforcement plate (on the underside of the engine)?

I'm gonna have to either run it without the plate or make cuts/notches and possibly reweld the plate to fit around some things.

 

[GuidoK]

I'm gonna have to either run it without the plate or make cuts/notches and possibly reweld the plate to fit around some things.

make sure you keep the integrity of the plate.
It serves as a trampezium shaped frame that incorporates the front suspension subframe into a box section/cubical frame (so the boxsection goes from chassistub (where the plate is bolted on next to the lollypops) to subframe, to front chassisarms to tub/plate)

 

[kis]

*incomplete, lots more photos and info to come*

Good! I love a good build! Keep the posts/photos coming! opcorn:

 

[vbelsky]

Youtube link added to original post. Didn't embed for whatever reason. :|

 

[enzed4]

Wow, just wow....

 

[Vanne]

Awesome!!! congrats, very cool build and sounds absolutely great. Subbed!!

 

[skelters]

Fixed it for you..

[youtube]FLfUtnFQEuw[/youtube]

 

[vbelsky]

Fixed it for you..

Thank you Updated the original post.

Awesome!!! congrats, very cool build and sounds absolutely great. Subbed!!

Much appreciated