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Old 10-10-2019, 12:57 AM   #1
VladBelsky
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Join Date: Mar 2014
Location: Tampa Bay, Florida
Posts: 98
My Ride: E46 roadster/E85 Z4
Year: 2003
Model: 3.0i
Transmission: 6-speed
Turbo Z4 Roadster Build

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 (XS Power anti-surge GT35R)

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
Ball bearing compressor and journal bearing turbine






Achilles Motorsport oil pan baffle to keep oil around the pickup tube. Good precaution if I'm gonna make the car fast.


Engine before installation


Oil drain from the turbo is a straight shot right into the 5/8in (16mm) barb at the oil pan.




Air intake to the turbo. 2.5" tubing. I may make a 3" or 2.75" one later on if it proves to be a restriction.


Charge piping under the subframe. Should work for now and I don't plan to lower the car.
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Last edited by VladBelsky; 10-16-2019 at 12:34 AM.
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Old 10-10-2019, 12:58 AM   #2
VladBelsky
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Join Date: Mar 2014
Location: Tampa Bay, Florida
Posts: 98
My Ride: E46 roadster/E85 Z4
Year: 2003
Model: 3.0i
Transmission: 6-speed
List of items purchased and costs for the build

*anything marked red is a planned upgrade

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
Valeo 835101 240mm single mass conversion kit - $505
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
Used Bosch 1800kh/hr MAF - $35
WALBRO/TI GSS340 255LPH Fuel Pump - $80

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 - $260
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

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 BKR8EIX (set of 6) - $42

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

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

Total:
$3853 USD
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Last edited by VladBelsky; 10-16-2019 at 12:46 AM.
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Old 10-10-2019, 12:58 AM   #3
VladBelsky
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Join Date: Mar 2014
Location: Tampa Bay, Florida
Posts: 98
My Ride: E46 roadster/E85 Z4
Year: 2003
Model: 3.0i
Transmission: 6-speed
Aaaaand gonna grab this box for videos/additional photos/links
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Old 11-07-2019, 09:17 AM   #4
PeteyTrades
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I'm excited to see more. Subbed
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Old 11-08-2019, 03:54 AM   #5
busin
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could you post more details about MS45->MS43 conversion please?
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Old 11-16-2019, 01:47 AM   #6
VladBelsky
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Location: Tampa Bay, Florida
Posts: 98
My Ride: E46 roadster/E85 Z4
Year: 2003
Model: 3.0i
Transmission: 6-speed
Quote:
Originally Posted by busin View Post
could you post more details about MS45->MS43 conversion please?
https://z4-forum.com/forum/viewtopic.php?t=111341
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Old Yesterday, 07:51 AM   #7
busin
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Quote:
Originally Posted by VladBelsky View Post
Many thanks!
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