Modifying a BMW TD manifold For yer Turbo setup

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JAMZ
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Post Sun Jul 30, 2006 9:27 pm

DONT DO IT!!!! :?

Dont go the modified TD manifold route if you go FI... geezers fkin christ

Complete and utter nightmare to get to them studs in the new positions on the manifold..
Cant get any leaverage as the stud nuts are to close to the actual maifold so you cant get sockets,spanners on..complete PITA.. i know why people just buy a custom turbo maifold now

I just put exaust wrap on thats one 15 miles tops...looks now like its been there for 3 mths
rocker box cover newly painted which is now chipped......3 times :(

GRRrr

Took the car for a drive today and saw smoke..shat myself as it looked like it was coming from the Turbo..after getting it up on stands and taking charge pipes off,downpipe off,Cold feed off... noticed ive got oil running onto the manifold behind the turbo and with my setup around that area is bloomin tight...after more inspection i found 4 studs were lose on the bottom side..and there are a a right PITA to get any decent torque cuz of there new positions...gunna get some new studs tomoz and try again as im too pi$$ed off now to do any more work..plus ive done enough talking and swearing to myself for the neighbours to think WTF is he going on about :wink:

My setup dont look so nice now :(

One thing after another and i dont even use the dam car..!
JAMZ
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Post Mon Jul 31, 2006 7:20 pm

Jon.. didnt bother to ring yer back as yer phone reception sucked... :?

Anyway.. i maanged to get replacement bolts which were about 10cm long that i used for studs.. seemed to go in ok so hope i havent done any DMG.. i only screwed em in enough so i could then do the OEM nut up on the thread enough to get a good hold..complete PITA...

After doing those 2 and then changed a few more while i was there i put the turbo parts back together then fired it up again hoping the smoke/leak had gone.... :o smoke still there and now i completely pi$$3d off as the phone call prolly told yer..weird thing was i let the engine run for 15 mins and it was still smoking so i 'thought' it couldnt just be the remains of yesterday burning off...

25 mins later.....no smoke :D

gunna take it for a run in a min and see what happens..only way to be sure

At the end of today i cut away that piece of valance in front of the IC... now i got mesh covering that and the oil cooler vent

looks :cool:
JAMZ
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Post Mon Jul 31, 2006 8:16 pm

Well.. cant see anything after my lil drive..still smell oil a bit but thats cuz of the breather arrangement ive got going on..its not circulating but is connected to a gauze like a lil chimney tucked away in the engine bay:)

Strange thing is that the turbo sounds a bit different now...not sure why and only hope its for the best..maybe i was having a small leak from the manifold before...not sure but it is different..

Still trying to get the optimum Oil amount into the turbo..donest seem to make any differnece where i turn the feed to as its a tap... got a feeling as long as its not on the 'Off' position im governed by the size of piping anyway which is restricting it enough on its way up
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blingsta
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Post Mon Jul 31, 2006 10:56 pm

So Jamz, tell me... after all the hard work thats been put in to the conversion, and considering the end result.. would you do it again if you went back in time?? :?:
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Post Tue Aug 01, 2006 11:43 am

Hi Bling..

TBH m8 i would...why? cuz of the price involved... this setup cost me in the region of 700 notes all in... youd buy a second hand Turbo for that and maybe have a bit left over to go towards yer manifold...you might be lucky and get both but then youve still got the IC,Charge pipes,Cold side to sort,Wastegate?..Oil lines,feeds,switches..modify yer AFM and get some sort of Fuel management or go standalone..bigger injectors too

Loads to do m8 and you can see why a typical Turbo setup would set yer back between 1800-2500k if yer lucky (WITHOUT Standalone/MS) then you got the time involved,fabrication which is more Dollar.. it aint cheap

Now bare that in mind with my setup that can run in its present form up to a Bar of boost and i got everything stock still..even the dam Motronic..this will have the MS setup soon enough then i could possibly up it even more than a Bar depending on how the IC hold up but then im looking at changing Hoses for Pipes so they can handle the pressure..

Dam..im sounding like a Boost junkie already..only had it couple of weeks :cool:

We were sort of govererned by time so things could of been done slightly different when it comes to the Manifold..i.e using longer home-made studs on the 2-3 that you cant get too..this is only because where you have to drill the manifold for it to line up properly and ypou get yer stud/nut in there, your so dam close to the actual body of the manifold you cant get the nut to turn or get any sort of decent leaverage with sockets/spanner etc and the 2 nuts on 1 stud trick is useless..everything was tried and everything failed..i went to B&Q and got what looked the same size nut as described in the previous post...not sure on the heat situ with these so i got to keep an eys on em..but i know the thread size so any decent fabrication/hardware place worth there salt will be able to provide me with the sam,e type of metal,thread size as stock OEM ones but just longer.. that would be the only advice i would give someone doing this conversion...get them studs/bolts sorted first..save yer bags and bags of time and frustration.

I havent drove it loads..im on bottletops ffs so i dont go near people.. :D (cheers Ian :wink: ) but it seems relaible enough,manifold coming lose was one of them things..i had the engine hoisted remember few days ago to change mounts..could of been the culpret

Engine mounts needed to be changed anyway so no biggie there..

when i post pics your see how clean it all looks...it bares no resemblence to Jon_bmw's setup when he had it..the only thing the same is the turbo/manifold position..he invented/worked on something which he was happy with and had no reason to change it..he got what he wanted and was very impressed and so he should be...very knowledgable bloke..but now its clean,blends right into the engine bay and tbh unless you stuck yer head in you wouldnt even know it was there

If anyone went wrong now then it would be the same things/problems you would have if you brought any second hand turbo setup or tbh even new setups cause problems...ask the guys :cool:

What would i do diffrently which ive sort of answered already:

**Sort manifold studs x 3 to longer reach

**Try a different IC..works well but position of inlet and outlet stubs could be better,my charge pipes are pulled away from the fan blades by clips/cable ties ets as to not hit the fan blades and which themselves have been modded/shaped to give me alil bit more clearence but as to not comprimise there effectiveness..so a custom made e30 one or another secondhand one would be used..

Upgrade?:

**You can upgrade yer IC to a bigger area one that fits infront of yer RAD..might have to ditch yer fan and get an electric fan instead but these mods will allow alot more boost which has been cooled enough to help with knocking/det syndrome

**Megasquirt

**Turbo is a mitusbishi TD04..used in the early Scoobies,used in MR2's,Shoguns...heap loads of cars which will surprise you...i was once i started to google and saw what applications it is used in..you can TD05/06...ther TD05 is comparable to the T3 turbo..maybe a touch better infact..TD06,lol dont think you would need that much power!

So there yer have it....basic answer to yer question is YES i would..the post topic reflects my anquish but this tpoic sheds some light onto the conversion..

Manifold and fabrication of downpipes is in my unexperienced view the main thing to think about,and more than likely the most expensive unless your buying new Turbo's etc

HTH
JAMZ
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Post Tue Aug 01, 2006 11:48 am

Oh and this time Sunday i was too beating said thing with a drum stick like the man in my Sig..it does drive you 'that' crazy!
Jon_Bmw
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Post Tue Aug 01, 2006 1:59 pm

Sorry about my shed of a mobile phone Carl! Its only got bad in the last month, it is about 4 years old :o

Looks so much neater and is definatly more powerful now. You need to get some pictures up dude, I wanna see that exhaust wrap for one.

Hmm i might need some bottle tops so that I can sell the hartge wheels soon, makes some money back that way. God I hate bottle tops.
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blingsta
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Post Tue Aug 01, 2006 2:11 pm

i think that before you know it, your going to upgrade/change a few things which is going to end up costing you, the same it would have to get a t3 turbo and m/s.. but aslong as your happy with it all mate, thats what matters! Oh yeah, i saw in your other post, the thingy you got for the gauges to go in...is that a perfect fit and how comes you got 3 of them?
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blingsta
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Post Tue Aug 01, 2006 2:12 pm

yeah mate, i wanna see pics dude,
JAMZ
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Post Tue Aug 01, 2006 3:32 pm

blingsta wrote:i think that before you know it, your going to upgrade/change a few things which is going to end up costing you, the same it would have to get a t3 turbo and m/s.. but aslong as your happy with it all mate, thats what matters! Oh yeah, i saw in your other post, the thingy you got for the gauges to go in...is that a perfect fit and how comes you got 3 of them?
No it wont dude..will cost no where near that.. ive got 700-1000 sitting here now dont forget..and who said anything about going T3..lol its the norm but doent make it better,as i said you can upgrade to TD05 which would cost me 250-350 and that is without what i would get for my TD04 :) and il have the same amount of power,much more acceleration if i went for the Diesel unit maybe less grunt on the M-way but i know which id rather have..

This setup and a secondhand/new T3 custom manifold pipes IC MS are miles away from each outher in prices involved...trust me!

As a ball-park figure not inc MS in both setups,ive prolly saved £1500 maybe more.

:)
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jamesc
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Post Tue Aug 01, 2006 4:25 pm

Jamz, Does the TD04 bolt straight onto the TD manifold? I've picked up a TD manifold with the orig turbo but I think I might need to replace it as it seems a bit small :D

Cheers, James
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JAMZ
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Post Tue Aug 01, 2006 5:35 pm

Was it from the 525?.. the TD04 isnt a big turbo m8..but its got huge amounts of grunt..once i got piccies up ypur be able to conpare em but i got a few things to sort first :cool:

As it is the Turbo needs to be fitted diferently as its on the bottom of the Mani now and needs to be on top, and then the turbo will need to be stripped and clocked so the Oil feed is on top and the drain is on the bottom then put back together..while yer there it would be a good time to changed the Rings inside.

hth