E30 325e to 325i Turbo

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MaikelK
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E30 325e to 325i Turbo

Postby MaikelK » Sat Mar 02, 2013 8:17 am

Hello,

I'm Maikel and i'm from the really small place Den Oever in the beautifull country The Netherlands.
I bought and E30 320i as my first car but had some bad luck with that car i sould this car after i swapped an engine in with 380.000k on the clock.
Then i bought an E46 320i wich is my daily driver at the moment.
But i missed my E30 and so i searched for one that i liked. I was looking for the 325e. 2.7liter and some extra torque.

I found one car, it was imported from Germany from the first owner. The man i bought it from was thinking of putting it on Dutch license plates but dicided
to not make that costs as he wanted to sell this car and buy an 7 series from Germany. So i bought his 325e from 1985 with Sunroof and foglights in front.
Car has complete maintenance history and even the orginele bill of purchase.

So i will now paste some text with pictures from a Dutch forum about my 325i turbo build.
I will translate it as i go i think, but if you want to read it, use Google translate or something like that haha :lol:

What i have bought so far
-M20B25
-Holset HX35w turbo
-TiAL F38 38mm wastegate
-TiAL 50mm blow off valve
-8x Bosch 0280155811 Injectors van 360-380cc/min van een Mustang 5liter
-Gasket sets
-28"x9"x2.5" intercooler, outside dimensions!
-Holset HX35w bearingkit
-kdFI Motorcomputer
-Conrod bolts
-Main bearing
-Connecting rod bearings
-Piston rings
-M10x1,5x150mm 12,9 inbus bolts for cilinder head

What to order
-Clutch pressure plate
-Guages

Engine block is completly overhauld, Pistons are reused.
Cilinderhead has 6 new exhaust valve guides and the valves and valve seats are grinded to match

Some pics of how it should look like.
Intercooler
Turbo ongeveer plaatsing

De link to the webalbum, there are more pictures then here in the topic

The engine block
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Homemade engine stand
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Turbo position, using two exhaust manifold of cilinder of cilinders 4-6 gebruik makend van 2 uitlaat spruitstukken van cilinder 4-5-6!
Where i work we have some small little turbos with exhaustflanges like the ones on the exhaust headers.
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New stuf and the engine block has been honend. On the last picture you can see that the compressorwheel is damaged, i need to order a new one
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More new stuff. Turbo repair kit and the kdFi engine control. And the intercooler!
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----------------------------------------------------------------------
18-9-2012

Mainbearings and crankshaft has been placed and axiaalclearance is well within specification:
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1 cilinder had a light overheatingwear sign, at a local E30 racing company i bought a goodlooking second hand piston for 10 euro. Put the piston on my own connecting rod. After that cleaned all pistonring grooves with an old broken piston ring. Cleaned the piston with a copper brush and fitted the new rings.
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I orderd the "metric blue" style headbolts. Was planning on oringing the block, but im not going to do this, first i will try to make 300hp. Then we will see after whats next. At a colleges house i picked up an pistonringguide to fit the pistons tomorrow.

-------------------------------------------

19-09-2012

Brought the cilinderhead to a guy that works at an engine overhaul shop. He will rebuild my head. He will fit 6 new exhaustvalve guides as there was to much space on it. He will resurface the valves and valveseats to match them.

Also a few weeks ago i rebuild the turbo. New bearings and cleaned all parts.
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----------------------------------------------
02-10-2012

Fitted the pistons and thigtent the connecting rods.

First 20nm, then 70 degress.
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Painted the block black
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Was going to fit the cilinderhead today, but checked my turbo position first. Found that oil cooler lines are i the way with
the manifold design is was willing to build.
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At work looked for the right size coupling to fit.
With a 90 degree elbow it will better.

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As you can see, it fits much better. But i have to bent the oil lines or make some new ones.

--------------------------------------

18-10-12

A friend of mine has lasercut 2 flanges, 5 minutes of work and 20 euro further, i have 2 flanges. (one for backup haha)

Tonight with my father started with the manifold.
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A movie from the BOV
https://picasaweb.google.com/1062042226 ... 8102876034[/quote]

-----------------------------------------

06-01-2013

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Fitted the cilinderhead and thightend the head with M10x1,5 12,9 bolts

Glaspearlbeated the rockercover, intake manifold and turbo compressor housing in our own sandbeatingbox

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Fitted the new distributionbelt and tensioner and checked the timing. Also fitted the new waterpump

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Again i have let my friend lasercut two flanged for the exhaustside of the turbo. Threaded a M10 hole to fit a bolt that can hold the wastegatehole plug in place.
I grinded off the wastegateshaft and made two plugs, one for where the wastegate was and one for the shaft hole.
On the flange i welded a small pieces of pipe to get rid of the opening where normally the wastegate exhaustgases flow into the exhaustpipe when bypassing the turbo.
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31-1-2013

-Fitted the intakemanifold and the "bitchpipe".

-Fitted the wastegate on a postion that i think is okay.
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-Thightend the crankshaft and camshaftnut.
-Glaspearlbeated the protectioncover and lifting eye.
-Fitted vibrationdamper
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-Making oil lines.
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----------------------------------------------------------------
Well,

The exhaustmanifold was almost finished, but i put it in the old iron bin.
Too less measuring, to much welding.
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Made the oil drain connection on the oilsump. When the engine is not running, oil is just standing in the drain, when running it complete open.
Inner diameter is 18mm, as recommended by Holset.
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Refitted the orginal manifold for cil 123, and build a new manifold.
Started with a friend of mine, and i decided to make it splitpulse now we were doing it over.
Should give so extra power or so.
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I fitted the injecors on the fuel rail,
and i can now check my KDFI with bluetooth in combination with ShadowDash MS van EFIAnalythics!


-----------------------------

2-5-2013

So,

An update after a long time haha, not so much time on hand, work and stuff!

-New manifold has been tig welded
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-After waisting a lot of 22mm hydrolic line, i choose for hydrolic hose. I should have done this from the start, now i wasted 60 euro's on scrap pipe.
This has been tig welded, this is prettier then CO2 welding, and hopefully, air thight, but i have to put some pressure on it to check this!
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-Made a small as possible 4 way pieces, one connection for the oilpressure light, one for an oil pressure gauge and from the block to the turbo feed.
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-End product turbo oil feed and drain.
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-Started with the downpijp, the rest will be made when engine is in the car.
Used v-band clamps, so the downpipe or the tailpipe is easy to remove!
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-Oil sump is mounted and the rear crankshaftseal with flywheel and gearbox. Engine is now standing on a frame, as i would like to test everything outside of the car.
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The turbo has been balanced, not top notch results, but with eBay compressorwheel and eBay bearing kit, they where very suprissed!
Last edited by MaikelK on Thu May 02, 2013 12:36 pm, edited 3 times in total.
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Yoshi
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Re: E30 325e to 325i Turbo

Postby Yoshi » Sat Mar 02, 2013 3:08 pm

Pretty classis but awesome project you have going on there. Welcome!
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Status: HG repair. 488wtq though!
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M20_fever
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Re: E30 325e to 325i Turbo

Postby M20_fever » Sat Mar 02, 2013 3:09 pm

Nice looking build. Translation would be nice though. So are you using the internal wastegate in the HX35 or did you plug it for an external one?

welcome to e3p!
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MaikelK
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Location: Noord-Holland, Netherlands

Re: E30 325e to 325i Turbo

Postby MaikelK » Sat Mar 02, 2013 3:39 pm

As you can see in the last few pictures, im using an external 38mm Tial wastegate.
I made some plugs on the lathe machine to plug the holes in the turbohousing.

I will try to translate some text this week, right now im away with some friends.
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Yoshi
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Re: E30 325e to 325i Turbo

Postby Yoshi » Sat Mar 02, 2013 10:27 pm

plug what holes?
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Status: HG repair. 488wtq though!
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Ryki
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Re: E30 325e to 325i Turbo

Postby Ryki » Sun Mar 03, 2013 4:53 am

Mmm the pictures! This actually turned into my wife showing me the difference between Dutch and German : )
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Nsquared97
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Re: E30 325e to 325i Turbo

Postby Nsquared97 » Sun Mar 03, 2013 5:50 am

I like this guy haha. Welcome man!
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MaikelK
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Re: E30 325e to 325i Turbo

Postby MaikelK » Mon Mar 04, 2013 12:09 pm

The holes where normally the shaft for the wastegate was sitting and the hole where the exhaustgasses should pass through:

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Yoshi
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Re: E30 325e to 325i Turbo

Postby Yoshi » Mon Mar 04, 2013 12:25 pm

gotcha!
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Status: HG repair. 488wtq though!
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blasphemy101
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Re: E30 325e to 325i Turbo

Postby blasphemy101 » Mon Mar 04, 2013 2:48 pm

Welcome! I like where this is going.

I wonder what happened to the first manifold design - I've never seen anyone go that route.
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87e30
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Re: E30 325e to 325i Turbo

Postby 87e30 » Thu Mar 07, 2013 12:37 am

Looking at this makes me REALLY wish I knew how to weld. Also makes me wish I had time to rip my spare engine apart and start rebuilding it.
Schwarz 5-speed 87 325is (newest project)
Arktisblau 5-speed 86 325e (current DD)
Schwarz 5-speed 87 325e (parts car/LS1 swap?)
Gazellenbeige automatic 85 318i (70,000 miles)
Alpine white 5-speed 87 325is (my first e30, possibly for sale)
99 Suburban
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M20_fever
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Re: E30 325e to 325i Turbo

Postby M20_fever » Thu Mar 07, 2013 1:38 am

Welding is easy, just takes practice. Decent starter rigs are getting so cheap its almost a must have for the serious DIY'er.
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Yoshi
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Re: E30 325e to 325i Turbo

Postby Yoshi » Thu Mar 07, 2013 1:04 pm

point and zap really lol. The settings take a bit to figure out, the rest is simple.
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Status: HG repair. 488wtq though!
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blasphemy101
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Re: E30 325e to 325i Turbo

Postby blasphemy101 » Fri Mar 08, 2013 3:48 pm

Welding is easy, welding well, however...

Over the past couple of months, I've seen enough muffler-shop jobs to realize that it doesn't have to be pretty, as long as it sticks the pipes together. Of course, I'd never trust myself to weld anything structural like suspension or rollcages....
MaikelK
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Re: E30 325e to 325i Turbo

Postby MaikelK » Wed Mar 13, 2013 11:54 am

So, i translated everything to English, i did my best! -grin-

Today i recieved the Vband flanges for the exhaustpipe, an IAT sensor with pigtail and a electronic boostcontrol valve for if i want the crank up the boost.

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