e30 316 rebuild from Finland

[alantw-15]

That red E30 is insane

that red e30 defies sense, never seen a bmw hook and move so quick!!
love how ye all do bmws in that part of the world, it's not that ye build a few turbo bmws, its that everybody 'completes' they're bm with a turbo

[Pazi88]

And continue with the build. My SD-card in camera just corrupted and I don't have any pictures of the process. Although nothing special hasn't happened Only thing I have are few videos which I moved from card earlier and videos I recorded with phone. So I only have videos to show.

For the brown turbo I got new engine block with pistons so I can fix the damage caused by bent rod. Before doing anything to it I decided to time-sert the threads for future proofing. Here's video about that:
[ame="http://www.youtube.com/watch?v=lXGm5_Vogy4"]How to install Time-serts on BMW M52/M54 block (head bolt thread repair) - YouTube[/ame]

And also we have started the turbo project for the ONE. Here's first part of the project videos:
[ame="http://www.youtube.com/watch?v=B78iA6vmU6I"]How to turbo BMW m50/m52 engine, part 1 - YouTube[/ame]

[Pazi88]

Great work on everything. That was some rust horror alright!

Yeah it was most horrible amount of rust I have ever seen

But now the pictures that were missing from last post. The turbo at our garage and laser cut flanges for exhaust manifold:


Right away we tear apart the turbo:


The wastegate hole was very small so I grined it bigger and alos port matched the exhaust housing with the manifold flange:


The compressor housing was panted black:




And if you want to see more detailed process, here is next part in youtube:
[ame="http://www.youtube.com/watch?v=-kKFeT_xxpU"]How to turbo BMW m50/m52 engine, part 2 - Cheap eBay turbo - YouTube[/ame]

The next part should be out in about two weeks and it's about the turbo oil lines and coolant hoses:

But to make the oil lines we took apart the front of the car:


Intercoorel is mouned in the same way as in my turbo:


For the turbo oil return we had to take off the engine front cover. And to do that part of the chain drive had to disassembled.




The oil return in front cover is 1 inch hydraulic fitting:


I drilled the hole in that bigger, because there was lot of extra material to do that.

The return "hose" is flex peace from hydraulic store. Should hold up to 10 bar pressure:


Installed:


Here is turbo oil feed and some coolant hoses:


We also got the injectors. These are 600 something cc siemens deka injectors:


And also some tube and bends for exhaust manifold:

[DER E30]

Awesome. Keep it up! How many WHP are you shooting for?

[Pazi88]

Awesome. Keep it up! How many WHP are you shooting for?

Do you mean engine HP measured from wheels or the HP from wheels?

Hah, just nitpicking because lot of people seem to confuse those two. We are aiming to 300-400 HP from engine but after taking that turbo apart, I think that 400 HP might be impossible with that turbo.

[Pazi88]

New episode is out at youtube:
[ame="http://www.youtube.com/watch?v=fWF6LV1UDN0"]How to turbo BMW m50/m52 engine, part 3 - Turbo oil and coolant lines - YouTube[/ame]

We are currently working on turbo manifold for the ONE. Here is few pics:








Our everlast TIG just died in that point, so we have to finis it using MIG welder. Hopefully it will still be good enough. The welding is alredy done and the manifold is now at the machine shop to get the flanges straight,

My turbo still waits in garage for attention. I have all the parts to fix the engine and I managed to buy m54b30 intake cam for more power. I'm also upgrading the tires for these Yokohamas:

[Welfare]

Both builds are amazing.

[Angrywriter]

Man, what size of fenders you have used?

[Pazi88]

Last weekend I finally had time to start working with my e30 turbo and immediately took out the engine. Of course I first had to run the engine to hear it last time. And to get the pumps and injectors running because ethanol fuel can clog them:

https://www.instagram.com/p/BDII5DnHD2D/?taken-by=sipasema

Engine out:


Looks quite empty:


I could do this even my eye closed because I have done this so many times.




Block emptied:


I didn't have time to investigate the engine but here is something I found on first glimpse. unfortunately couldn't find anything that would cause the shaky engine at medium throttle (which is the reason I took apart the engine).

But the things I found:

- Small metallic bits on the oil pan and metal in oil. No idea where the bits are, but the metal is from cylinder walls.
- Pistons are in ok condition.
- Ring gaps are in spec.
- No bent connecting rods this time.
- cylinder walls have mirror finish
- bearings have something in them but not bad.
- Need to polish few journals from crank.

But the most interesting fact is that the piston are the wrong ones for teh engine. They look like pistons for the dual vanos engine. And also they are with wrong diameter for the engine. The max clearance between cylinder wall and piston should be 0,15 mm and these had about 1 mm clearance. The wear on cylinder walls couldn't cause this because ring gaps are still in spec.

Looks like the guy who had rebuild this engine in England had no idea what to do. Previously I have found crooked head that has not been resurfaced and oil pump has been assembled wrong with broken parts. And now wrong pistons.

Now plan is to correctly assemble the engine to spec. The wear on cylinder walls may have been caused by the wrong size pistons on too rich fuel (ethanol wears out the oil). I will lean the mixture on my tune to fix this. And for the shaky engine I can't find any other reason than wrong cams (more lift and duration on exhaust side.) So I will change the intake cam to m54b30 one. That seems to work in my daily.

[Pazi88]

Here is the project videos in youtube about that engine removal and disassembly I told in previous post:

[ame="http://www.youtube.com/watch?v=NFUbSe8nY8I"]BMW e30 m52 turbo winter maintenance. Part 1 Engine removal - YouTube[/ame]

[ame="http://www.youtube.com/watch?v=MJiqpL9f0u8"]BMW e30 m52 turbo winter maintenance. Part 2 Engine disassembly - YouTube[/ame]

[Pazi88]

Here is the next part of m50 turbo build:
[ame="http://www.youtube.com/watch?v=DQzM3ZxxQYE"]http://www.youtube.com/watch?v=DQzM3ZxxQYE[/ame]

The process with the car is bit further than is shown in he video.

To get thew new bigger tires to fit with the e36 struts we needed to bring the wheel to the center of the wheel arch. To achieve that we changed the front wishbones to e36 M3 3.2 (EURO) ones. With those the wheel moves few centimeters:


Rear bushings are still from M3:


I replaced the shitty wideband lambda connector from KDFI port with straight wires to the Bosch LSU 4.2 connector to get the lambda work more robust. Also added wires for electronic boost controller and launch control. The third one is for extra digital input for future mods.


And now the car looks like this:








We will assemble the car to that point in next video which should be out next week so tune in.

[PedroM]

Quite awesome build! More videos!

[loekaaz]

That paint on the headers makes it look like it's red hot F1 style