2.8 turbo

[Delk]

I bow down to your skills sir

A lot can go wrong. It's fingers crossed until it's running.

 

[B21]

Very very impressive …

What version of BMW engine was the 2.8?

Apart from ‘because I can’..what’s the logic of the new engine ?

 

[Delk]

First version is the 2.8TU. Reason behind it was the few HP from a M54 intake manifold and basic mods were not enough.

2nd engine is 3ltr M54 with all new internals. Forged rods, pistons, upgraded oil pump and so on to ensure reliability. Reason for this is simple addiction, 400hp doesn't seem enough.

 

[B21]

First version is the 2.8TU. Reason behind it was the few HP from a M54 intake manifold and basic mods were not enough.

2nd engine is 3ltr M54 with all new internals. Forged rods, pistons, upgraded oil pump and so on to ensure reliability. Reason for this is simple addiction, 400hp doesn't seem enough.

I thought the mark 1 version was making 500bhp+?

I admire your focus, tenacity and skills

 

[Delk]

Mk1 is 425hp. It could make more but the stock bottom end is more then questionable at that figure.

The boost controller failed on one of the Dyno runs and it made a lot more power and we were all surprised it was still in one piece after seeing 2 bar plus of boost. Mk2 won't have that concern and the new turbo will come on sooner so even better.

 

[B21]

Mk1 is 425hp. It could make more but the stock bottom end is more then questionable at that figure.

The boost controller failed on one of the Dyno runs and it made a lot more power and we were all surprised it was still in one piece after seeing 2 bar plus of boost. Mk2 won't have that concern and the new turbo will come on sooner so even better.

Thnx for the feedback…my 35is is now around 525-545 crank BHP and 750 nm torque ..on 23 psi tapering to 21 psi..with a Quaife lsd and all the Nannie’s…if you let it rip it’s almost mind bending….so I look forward to the Z3 with even more power

 

[Delk]

Thnx for the feedback…my 35is is now around 525-545 crank BHP and 750 nm torque ..on 23 psi tapering to 21 psi..with a Quaife lsd and all the Nannie’s…if you let it rip it’s almost mind bending….so I look forward to the Z3 with even more power

Thee N54 is a great engine and can produce a boat load of power right out of the box. Have you done a single turbo conversion or anything?

 

[B21]

Thee N54 is a great engine and can produce a boat load of power right out of the box. Have you done a single turbo conversion or anything?

I’ve gone for a pair of German TTE500 hybrid turbos ..faster spool than a single turbo …and compared to the original dyno curves and even the re-map on the stock turbos it revs out …previously by 5500 you were past peak power ….feels fabulous..but..lots of torque so on a wet road in 7th I can spin the wheels gently overtaking even with a Quaife…and 275 conti sports contacts..so for me I’ve arrived…after about 600 crank BHP there are lots of stress related issues appearing ..so again good time to stop…

 

[Delk]

Today was engine removal day. I have worked on this car far to much. From the point it was lifted off the ground it was three hours until the engine was out. Will take a whole lot longer to fit the new one with all the changes.
I was very surprised at how clean the intake valves were. The stock crank vent system was removed when the turbo went in and it catches a lot of moisture and filth. Intake ports are spotless.

 

[B21]

Today was engine removal day. I have worked on this car far to much. From the point it was lifted off the ground it was three hours until the engine was out. Will take a whole lot longer to fit the new one with all the changes.
I was very surprised at how clean the intake valves were. The stock crank vent system was removed when the turbo went in and it catches a lot of moisture and filth. Intake ports are spotless.

Port injection Zeds run a lot cleaner than direct injection Zeds..the N54 is notorious for coking up its inlet’s..the later N20/N55 had better control of the recirculation system so wasn’t as bad…

Looking forward to the install..

 

[Moddedmark]

I know have 500 miles on the turbo build and its running great. Still needs its final tune at the end of the month but other then that I am happy. Other then the pops and bangs on deceleration.

Fuel consumption is not great but that's because my foot and not the car. Driving impressions are normal until you give it some pedal. I have driven several long trips now from Norfolk to Hull and back and doing four hours at a time puts some confidence in the car again after it has been in pieces.

I am also really happy with the new tires and wheels on the car. I change to Michelin pilot sports and they are night and day compared to the Goodyears on the car before. I cant say its just the brands as the size changed also but there is a notice difference in the grip. The old ones used to feel as if they would just break away and loose all traction. These are just more settled and you seam to be able to drive to the limit and they dont punish you near as much for going over. The car now has 245 fronts and 295. The rear was already narrowed with Z4 hubs and these are about the biggest I could fit without breaking the bank and starting down the road of major modifications. The wheels have custom offsets and nothing rubs.

Otherwise the car is riding on BC coil overs and all the bushings have been replaced over the last two years. Honda S2000 seats keep me in place and she has a nice new top installed this winter.

This project all started when I picked up a 330 intake manifold for more power. The more I thought about it I didnt think the amount of work was worth the return so I went further.

It was a steep learning curve but worked out in the end.
The MS43 DME running the TU engine is not supported and nobody modifies them so I had to go with a standalone. Everything works as original but I lost the traction control. I will talk with the tuners as I maybe able to wire this back in.
The other I experienced was my fault. I didn't remove the block from the car and choose to tap the turbo oil return into the boom right of the timing cover. This works on top mount turbos but my low mount didn't drain. Car smoked like it was in a 007 movie. In the end I fitted a scavenging pump to return the oil. A little noisy on startup but once the oil is warm its fine.

Holset HX35 turbo
Turbine housing Hx35 H1c WH1c Turbine Housing t3 .82
Exh manifold FTWL Mid mount
Wastegate Precision Turbo Wastegate 46mm Black PW46 PT#PBO085-2000
Blow off valve. Turbo smart 25mm plumb back
Air cooler 3" 76mm ALUMINIUM PERFORMANCE
Core Size: 445x300x76mm | Overall Size: 630x330x76mm
ECU Delta 800
MAP sensor
Head gasket REINZ 61-33070-00
Spacer 1mm
Head studs ARP 201-4302
Fuel pump WALBRO 255 FUEL PUMP
Injectors Bosch EV14 (specs?)
Wide band AEM X-Series Wideband UEGO AFR Sensor Controller Gauge # 30-0300
Plugs NGK BKR7EIX (2667)
Scavenging pump Mocal
Exhaust 3 inch down pipe splitting into a pair of 2.5 inch pipes. High flow cats and silencers.

I got a little carried away and fitted this all before doing the rear subframe. I will keep an eye on the spot welds and then stiffen it up next winter.

what would you estimate the cost of the turbo build side?

 

[Delk]

I have not kept track and don't even want to know. The first build wasn't cheap and my second engine even more. Been away for work so don't have it fitted yet.
A whole lot depends on your fabrication ability and how much you want out of it.
First build from memory
Holset HX35 turbo almost new but not. 350
Turbo exhaust housing 250
Exhaust manifold 350
Waste gate 350
Injectors 300
Head gasket 150
Head studs 200
Intercooler ?
Piping ?
Downpipe and exhaust several hundred plus my time welding.
I went with a stand alone ECU so that was about 1k with all the relevant sensors.
Tuning seval trips so probably 500
Gauges, bits and pieces add up.
Fuel pump 200

You can do it cheaper or spend more even easier.

Second engine
Garrett G30 turbo
Forged pistons
Forged rods
Headwork
Cutting head gasket
11mm head studs
Oil pump with chain guide
Bigger injectors and fuel pump
Aluminum intake
82mm drive by wire throttle body and adapter
List goes on

 

[Delk]

Been busy with work away but managed to get a week away for skiing. Second day in some young gall managed to take Ann-Marie out from behind and broke her arm so we are home early.
While she recovers I managed to get the new engine in before going away again. Still a lot of work to go as there are so many changes.
The intake clashes with the heater control solenoid and the power steering reservoir needs to be relocated amongst many other things.

 

[Scooblitz]

Been busy with work away but managed to get a week away for skiing. Second day in some young gall managed to take Ann-Marie out from behind and broke her arm so we are home early.
While she recovers I managed to get the new engine in before going away again. Still a lot of work to go as there are so many changes.
The intake clashes with the heater control solenoid and the power steering reservoir needs to be relocated amongst many other things.

View attachment 293241

Hope she is on the mend. Shame about the holiday too.

Some good work slotting the engine. Looking good.

 

[Delk]

Work got in the way for months so finally back at it.

Super happy yesterday as I got the new pedal and throttle body wired in and working. Lots more to do but that was a big worry.

 

[Sajk]

This post is tinged with a bit of envy but the question has to be asked about the appropriateness of this much power in the e36 compact platform. I rekon the s54 m version of the z3 was close to the ragged edge of the floppy chassis and decades old rear end.

Having said that I would love my 2.8 to go like yours but i rekon 350hp is a sane limit for the platform. Have fun, keep it on the road when you plant it.

 

[B21]

This post is tinged with a bit of envy but the question has to be asked about the appropriateness of this much power in the e36 compact platform. I rekon the s54 m version of the z3 was close to the ragged edge of the floppy chassis and decades old rear end.

Having said that I would love my 2.8 to go like yours but i rekon 350hp is a sane limit for the platform. Have fun, keep it on the road when you plant it.

Having watched BertieJaffa for a few hundred of miles going full tilt I’m not sure the Z3M can cope with the stock power!

 

[Delk]

Mainly it's doing it because I can and enjoy it.
But that said I have not heard many people ever say there is enough power. Happen to have a pair of 2.8 Z3s in the house and I love driving my turbo one over the Misses.

Making progress and hope to have the new engine up and running next week. Turns and has oil pressure. Just going through all the small jobs like getting the fuel system plumber.

 

[Dino D]

I used to think that too but a properly sorted M driven properly does not feel bendy or out of control - @Lee ’s S50 in the wet did things I didn’t think possible!

Yesterday watching the 60’s touring cars - minis, cortina’s, mustangs and massive boats (ford falcons) wobble round Brands hatch having fun made the modern stuff look seriously boring!

That said @Delk ’s turbo will be another animal.
Love n/a but also love some old school boost - I like you dual Z3 solution to that dilemma

 

[GZed]

I used to think that too but a properly sorted M driven properly does not feel bendy or out of control - @Lee ’s S50 in the wet did things I don’t think possible

Nuff said!

View: https://youtu.be/6q5SVHpN_CU?feature=shared