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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
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My Ride: E46 roadster/E85 Z4
Year: 2003
Model: 3.0i
Transmission: 6-speed
Turbo Z4 Roadster Build (w/ YouTube video link)

Hi, all. Sharing my '03 Z4 3.0i (E46 roadster ) bottom-mount turbo build.

Brief overview:

-MS43 ECU
-Has air conditioning
-CX racing GT35R journal bearing 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)

• 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
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Last edited by VladBelsky; 02-05-2020 at 03:54 PM.
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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: 100
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
• 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, an air intake- $650

Total:
$3975 USD
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Last edited by VladBelsky; 02-05-2020 at 03:27 PM.
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Old 10-10-2019, 12:58 AM   #3
VladBelsky
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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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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 11-20-2019, 07:51 AM   #7
busin
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Quote:
Originally Posted by VladBelsky View Post
Many thanks!
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Old 12-27-2019, 11:35 AM   #8
Sykriss
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Posts: 493
My Ride: 325XiT, 328i, 330Ci
Could you PM me a link to that exhaust manifold? Looks a bit better than a lot of the other log style ones I've seen

Edit: Nevermind, I found it on eBay, lol. However, I do have another question. I have a bottom mount turbo 330Ci and currently my charge piping interferes with the front subframe crossmember. How did you do your turbo-to-intercooler charge piping? Did you use a silicone elbow from the turbo? If so, any issues due to proximity with the exhaust manifold? I found a shop that would be willing to weld a metal elbow onto the turbo itself, but if I decided to swap turbos (which I very well might this spring), then I'd have to have it re-fabbed. Any insight is appreciated, thanks!

Last edited by Sykriss; 12-27-2019 at 11:47 AM.
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Old 01-15-2020, 12:49 PM   #9
MachRc
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My Ride: 2009 E89 Z4 35i
Beautiful build!!
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"This is ten percent luck.. Twenty percent skill.. Fifteen percent concentrated power of will. Five percent pleasure..
Fifty percent pain. And a hundred percent reason to remember the name...."
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Old 02-05-2020, 03:40 PM   #10
VladBelsky
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Location: Tampa Bay, Florida
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My Ride: E46 roadster/E85 Z4
Year: 2003
Model: 3.0i
Transmission: 6-speed
Quote:
Originally Posted by Sykriss View Post
...How did you do your turbo-to-intercooler charge piping? Did you use a silicone elbow from the turbo? If so, any issues due to proximity with the exhaust manifold? I found a shop that would be willing to weld a metal elbow onto the turbo itself, but if I decided to swap turbos (which I very well might this spring), then I'd have to have it re-fabbed. Any insight is appreciated, thanks!
I added a link to the original post that has some photos that will help you!
Also updated the post with a youtube video!

Quote:
Originally Posted by MachRc View Post
Beautiful build!!
Thank you
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