m20b25turbo...rebuild.(change of plan!)

[gcorky]

well thought id start my own thread for my build.
89 325i touring in malachite..gonna get boosted..
brand new holset h1c turbo 18cm3 turbing house,
itg stainless manifold,
catcam custom grind with less overlap..
ford racing 440 cc injectors,i bought from usa,
volvo ic in top nick,
polished ic piping kit,
3 metre plus elbows silicon hose for ic,
40 mm external gate plus flanges to weld on,
megasquirt kit inc loom ,sensors etc
innovate lm1/ lc1 wideband controller,
metric blue headbolts
polished aluminium turbo oil filter
bailey dv26 dump valve,spare generic dump valve.
polished catch tank,
boost gauge
ive fabricated the exhaust pipe from turbo with 02 boss and vband fitted.

this is most of stuff,yes theres more...lol


i have recently offered this turbo stuff for sale...but i cant stand the questions/messers , too many let downs,it was a good deal...and now...bugger it,ive spent more money today and have made the decision to realise my e30 dream!

so ive bought a 180k bottom end(cheers Ian)stripped it down and no wear to mention,but as its gonna get some smoke up its ass from the holset h1c...im gonna rebuild,new shells ,rings,seals,gaskets,oil pump+drv

ive cleaned,coated block in vht chevrolet red,modified sump to take the oil return-i did buy the landy td4 item but have gone for the bulkhead fitting option which is larger i.d...i also got some bukshee tubing and fabbed up the turbo return flange.got the stainless high temp hose with stainless super t clamps to match as shown....

so thats where im at,i will add in pics,specs as i do it..


oops nearly forget the cwp picture,i didnt realise the e36 m3 diff has same internals...e36 boys are buying the 3.91 diffs to swap in and of course their 3.15 s are up for grabs,so i got myself one....so another little job later on.


i must thank Ant,fozzymonster,turbobrown as there help and advice has been great...and they have been an inspiration from day 1...plus theyve gone through all this f.i build them selves so the advice is founded!!




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[oakey]

good luck with the project dude. thats gonna be one awesome car
sorry if you thought i was messing you about dude, i was just about to send you a message saying i'd take it whe i saw this thread

[gcorky]

good luck with the project dude. thats gonna be one awesome car
sorry if you thought i was messing you about dude, i was just about to send you a message saying i'd take it whe i saw this thread

nah wasnt you....but at the end of the day i didnt have a definate yes or no....and ive spent a bit more this week..and had let downs on other things..so i thought fook it,ill get cracking..i do know there are CHEAP kits out there,but honestly ive considered/read/researched a setup that has taken me over a year to get together and will pay off in terms of performance and longevity....long after a generic tubby has taken an engine out !


amen

[appletree]

Nice start looks like you've got all the gear anyway!! keep posting the pics up, nice to see some one who posts the step by step pics, as they say a picture speaks a thousand words



Am also to lazy to read all the words

[gcorky]

tell you one thing...core plugs were ok but i bashed em out to replace them....jesus,what a struggle...my usual sources dont wanna know! ecp or dealers here i come...and these engines are so well engineered 180k....no ridges,pistons still have machining marks all way round...all standard bore,journal sizes too....wished i had an e30 ten year ago now!

heres my tubster

heres a h1c next to a cozzy t3..

and heres the 5.9 litre cummins engine its native too(also in the dodge ram)
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[blingsta]

Good on ya Graham, go for it mate and good luck

[gcorky]

cheers Erel...hope your car is ok..

[cplagz]

Good luck with the build mate. I just finished assembling my motor this weekend, take ya time, check and recheck EVERYTHING

[gcorky]

Good luck with the build mate. I just finished assembling my motor this weekend, take ya time, check and recheck EVERYTHING

lol...why have you had a mishap here?

havnt got my mains yet.....so nothing much will progress ...for a couple of days..

ill glazebust bores tommorrrow and check the ring gaps...

[Morat]

Very best of luck gcorky! It sounds like you're building my dream car so I'll be following this one closely. Can't offer any worthwhile advice, but all the best with it.

[cplagz]

Good luck with the build mate. I just finished assembling my motor this weekend, take ya time, check and recheck EVERYTHING

lol...why have you had a mishap here?

havnt got my mains yet.....so nothing much will progress ...for a couple of days..

ill glazebust bores tommorrrow and check the ring gaps...

Nothing major, valve that was open happened to be in same bore piston was up in and we were stumped as to why the head wouldnt locate onto the dowels... then it clicked.

Also, oddly, we did valve clearances on head with new camshaft... left for a week, added some more cam lube and gave it a few rotations, bolted it to the block and the clearance's were all wrong again.

[gcorky]

well today glaze busted the bores and check the ring end gaps....tolerances are specified between .20mm and .50mm...
and i came in a lovely .28mm ,so im chuft with this 88 180 k lump!

so new oilpump plus drive,set of standard yellow mains,cam belt kit,big end bolts,core plugs,all ordered
dealer wanted 130 quid for mains...

all here wednesday hopefully.
i already have bigends,piston rings ....best not to buy all at once...not so scary...lol

updates,pics to follow.

[Morat]

dude, keep a list of all the parts - you might find some people wanting to follow in your footsteps!

[gcorky]

heres a few random pics.
1.measure ring end gap.
2.water pump fitted/plus aux shaft.
3.shows my remote t-piece from demon tweeks.
4...just the block on its side...showing how clean the internals are!



gonna clean it again tommorrow,chase threads,clean mating surfaces in prep for the build.








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[e30_Turbo]

Looking good Graham!

Although you know this rebuild & turbo moves you up to the next level with Alex & Ant as I just cheated and bolted everything on Big respect for getting it on and moving, looks like your well organised, those oil lines are superb as is the return setup, very nice

All I can remember from the first build was starting with a box of parts that didn't fit, a few lengths of pipe, a turbo, intercooler, ECU and a welder Still it was formed out of two days of cool memories and plenty of laughs so I hope yours is the same, then you get to test it!!

Can't even start to describe what it sounds like under full chat, can't wait to hear your thoughts too

How are you going to manage boost?

And how are you routing the exhaust?

And more pics!!

[gcorky]

How are you going to manage boost?

And how are you routing the exhaust?


not sure on either really,was gonna route exhaust as you did from same stuff....,boost control will be simple to start,till im somewhere near.....

ive mentioned before:plumb in an air pressure switch ,and a fast acting solenoid ,run as an isolated circuit..by this i mean no megasquirt controlling at this point....,but im open to suggestions on both.

i like the sound of a straight through skyline...loud

[cliffybabe]

i really enjoy seeing these build diary posts it really temps me into turboing my cab, hmmm really temped and now my bird has bought a VXR Astra that runs 240 bhp im really really temped

Looking good Gorky keep the pic's coming

[cplagz]

Looks good dude. Took me 3 days from bare block to assembled and bolted in the car (last night) most of it's all wired up, just gotta bolt ancillaries on and test fire.... then run in ...... then MS ..... then finally add the turbo

What size oil drain are you running? I had a AN-8 bulkhead fitting welded into the top front right corner of my oil pan.

[chrisr29]

ive mentioned before:plumb in an air pressure switch ,and a fast acting solenoid ,run as an isolated circuit..by this i mean no megasquirt controlling at this point....,but im open to suggestions on both.

I tried that once on a Rover 800 Turbo. It was either on or off...you'd hit max boost and the car would go into manic kangeroo mode as the waste gate opened and closed rapidly as boost was suddenly dumped then built again. It was a puka switch from RS Components, still got it if you want it? Will be interesting to see if you can get it running properly with this method....I geuss some sort of progresion would have to be built into the setup. I reverted back to a good old fashioned bleed valve in the end; crude but effective.

[gcorky]

ive mentioned before:plumb in an air pressure switch ,and a fast acting solenoid ,run as an isolated circuit..by this i mean no megasquirt controlling at this point....,but im open to suggestions on both.

I tried that once on a Rover 800 Turbo. It was either on or off...you'd hit max boost and the car would go into manic kangeroo mode as the waste gate opened and closed rapidly as boost was suddenly dumped then built again. It was a puka switch from RS Components, still got it if you want it? Will be interesting to see if you can get it running properly with this method....I geuss some sort of progresion would have to be built into the setup. I reverted back to a good old fashioned bleed valve in the end; crude but effective.

this would be the same with ms powering the solenoid....wouldnt it?solenoid is "on" or "off"?

id need to think about that i suppose.

[chrisr29]

That's a good point because the Rover actually used a solenoid to regulate the wastegate only it was controlled by the ecu via a MAP sensor. I guess the switch I used lacked the precision to make it work properly (it was a purely mechanical device after all) and was unable to cycle fast enough to permit any sort of fine control.....hmmm, food for thought.

[cplagz]

I'm going to be using a fast acting electronic solenoid to control the signal to my wastegate for boost control. Which will be mapped via MS.

[E30BeemerLad]

good on ya fella for not chucking the towel in.

Is Eddie at Teesside Auto Technical Services not any good for some of the more obscure parts, like the core plugs etc? I know they are mainly fueling/ignition people but he may be worth a punt?

[gcorky]

good on ya fella for not chucking the towel in.

Is Eddie at Teesside Auto Technical Services not any good for some of the more obscure parts, like the core plugs etc? I know they are mainly fueling/ignition people but he may be worth a punt?

as its old stuff now,he just gets it from preston hall bmw...

[gcorky]

mains come today.....hmn found something out....the original shells were stamped with a ks and bmw logo....because ks make them !so i bought the kobleschmidt(ks)for a third of the price.

also my block has the 180 degree oilways.....as opposed to 360.this makes the kit the same as the m50 one.

mounted crank and fitted core plugs today...used vht assembly lube .

its lovely putting new stuff together...

[gcorky]

well update pics...bottom end practically done.
pic 1:new oil pump and drive fitted,timing covers with new seals .
pic 2:sump fitted inc all new stainless bolts.
pic 3:turbo return is blocking one of bolts....but i got it in-just fiddly.
pic 4:made sure i could get return hose and clamp on!

recap.big end and main bearings renewed,big end/main bolts replaced,every gasket/seal replaced/glazrbusted and new rings fitted,new oil pump and drive,new waterpump,stainless sump bolts(most of external bolts will now be stainless).

painted pulleys ,covers etc...let dry over weekend.next week ill strip spare head and get cracking with that.

will take some pics of pistons etc..before head goes on!


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[gcorky]

update:stripped head last night....all ok -slight play in exhaust valve guides....which is usually the case!
so crack test/skim/new guides....not back till tuesday next week...bloody bank holidays!

also the itg manifold had 1.5mm warpage on its face....so thats been machined flat...so no progress till next week

might fit the tec2 door pods over weekend..

[cplagz]

Progress well mate, mines still sitting in garage refusing to start. Immob/Alarm/Central Locking issue I think (or hope)

[gcorky]

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update:
head back today,p/test+skim+new exhaust guides.test fitted the itg manifold and turbo (manifold skimmed as was 1.5mm out of true.)all ok now ,goes over studs sweet although two of the nuts are very tricky to reach.... .bonus is the plugs can be changed after all with manifold on....

been doing a bit of polishing last night! turbo compressor will be getting polished too.

[buster]

Nice work Graham,stick with it
What paint did you use on the block Can tell you work on big plant engines

Id maybe peen or weld that nut on the oil return on the sump also.Dont want it vibrating loose and dropping into the sump.

Keep up the updates

andy

[gcorky]

Nice work Graham,stick with it
What paint did you use on the block Can tell you work on big plant engines

Id maybe peen or weld that nut on the oil return on the sump also.Dont want it vibrating loose and dropping into the sump.

Keep up the updates

andy

cheers andy,paint is vht chevvy red or summit..hear what you say on the bulkhead fitting,but its not going anywhere .how can you tell what i work with?

[buster]

You going for custom pistons then or late 2.5 ones ?

[gcorky]

You going for custom pistons then or late 2.5 ones ?

pistons are the late type 83.98...bottom end is done....waiting for its lovely clean head....lol,vht copper cement,ellring hg,metric blues (cheers m8),cat cam with less overlap and so on.

well have to meet up when cars are done.

[buster]

yeah ,sounds good.Do you fancy your chances ?
I better get that 100 shot of nitrous fitted

[cplagz]

Try using ur flash on the camera, there's not enough light getting in the workshop which is why the shutter stays open longer and the pics are coming out blurry