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Turbo E85 Z4 Roadster Build- Bottom Mount w/ AC

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5.6K views 3 replies 1 participant last post by  VladBelsky  
V
#1 · (Edited)
Hi, all. Sharing my '03 Z4 3.0i (E46 roadster ;) ) bottom-mount turbo build.

*incomplete, lots more photos and info to come*

Brief overview:

-MS43 ECU
-Has air conditioning
-Chinese GT35R copy turbo
-Valeo 835101 single mass flywheel clutch kit
-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)

***8226; Compressor housing - .70 A/R
***8226; Turbine housing - .63 A/R
***8226; Compressor Wheel 61.3 /82 mm
***8226; Turbine Wheel 62 /67.8 mm
***8226; 4in. inlet and 2.5in outlet

https://www.youtube.com/watch?v=FLfUtnFQEuw

Link to my wheelwell page with tons more photos and info:
https://wheelwell.com/vlad-belsky/2rj3/2003-bmw-z4
 
V
#2 · (Edited)
List of items purchased and costs for the build

*anything marked red is a planned upgrade

Turbo Oil/Coolant feed
***8226; Rally Road Feed line (bottom mount)- $33
***8226; Rally Road Vanos bolt adapter to AN4 line- $33
***8226; M14x1.5 to 3/8 barb (coolant to block)- $9
***8226; 1/8 npt to 3/8 barb (coolant to lower rad hose)- $5
***8226; 36 mm coupler with 1/8npt hole- $10
***8226; Drain line (5/8 in pushlock hose and 3/4in heat shielding)- $20
***8226; 5/8in weld-on aluminum bung for oil drain- $5
***8226; Oil pan baffle kit and oil pan gasket- $204
***8226; 10ft 3/8in ID ss braided teflon line- $40

Clutch
***8226; Valeo 835101 240mm single mass conversion kit - $505
***8226; Clutch alignment tool - $8
***8226; Pivot pin brass - $18

Intercooler
***8226; 2.5in Pipe kit $72
***8226; Intercooler $80
***8226; Intercooler mounting materials - $20
***8226; Extra 2.5in 90 elbow - $9

Fuel System
***8226; Bosch 0280158123 630cc injectors - $250
***8226; Injector spacers - $40
***8226; Used Bosch 1800kh/hr MAF - $35
***8226; Deatschworks DW200 255lph fuel pump- $86

Exhaust
***8226; Manifold ($140 including labor to machine it)
***8226; VHT 2000F paint- $20
***8226; Dump tube and downpipe starter fab + material - $140
***8226; T304 stainless 3in V band clamps/flanges x 3 - $54
***8226; 8FT 304 stainless 3in pipe - $60

Turbo
***8226; Turbo - $300
***8226; Rally road E46 turbo engine mount arm w FEBI 15786/274111 engine mount -$180
***8226; Precision Turbo PW46 46mm Wastegate - $350
***8226; TiAL-style (Tial BV50 replica) 50mm Blow Off Valve - $54
***8226;-11lb spring for BOV - $15
***8226;Genuine Tial O ring for BOV - $5

Air Intake for Turbo
***8226; 4 in to 2.5 in 45 degree elbow/coupler - $10
***8226; 2.5in inlet cone filter - $14

Gaskets/Misc
***8226; Exhaust manifold gaskets (BMW part #11621728984)- $18
***8226; Copper spray Permatex 80697 - $10
***8226; M7 exhaust nuts part #11721437202- $10
***8226; Engine/trans mounts - $45
***8226; Spark plugs NGK BKR7E (set of 6) - $18

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

Fabrication costs
***8226; Oil pan modification labor- $100
***8226; Fabrication labor for exhaust, charge piping, an air intake- $650

Total:
$3975 USD
 
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