Turbo M54B30 2003 Z4 Roadster (E85 chassis) Build (Bottom Mount with AC)

[VladBelsky]

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


Brief overview:


-MS43 ECU
-Has air conditioning
-CX racing GT35R journal bearing turbo
-E83 X3 2.0d Luk clutch disc, eBay ClutchMax flywheel and pressure plate (needs to be installed; currently running a slipping Valeo 835101)
-M50 intake manifold and fuel rail (return is welded up)
-Bosch 0280158123 630cc injectors
-Bosch 0261230191 MAP sensor (before that, I used a 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





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

List of items purchased and costs for the build. Items in red need to be installed. Needs a new clutch because the Valeo 835101 kit I have in it now does not hold the torque.


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) and
E60 550i pressure plate (from Luk kit with BMW part # 21207573789), ended up using only the disc- $340
•ClutchMax S52/M52 15lb chromoly flywheel (surface needs to be machined 0.020in to accomodate the E83 diesel disc) w performance pressure plate (70% more clamping load, from their stage 3 kit) - $240
• 22-spline clutch alignment tool - $8
• Pivot pin (brass) - $18


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
• Bosch 0261230191 MAP sensor - $40
• 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:
$4045 USD

[Meeners]

Very cool rig... I love your approach to the build! It's simple, clean, and very well done.

[VladBelsky]

Very cool rig... I love your approach to the build! It's simple, clean, and very well done.

Thank you!