2.8 turbo

Dino D

Zorg Guru (V)
British Zeds
Joined
Mar 28, 2014
Points
176
Location
Kent
Model of Z
2.8 Manual
Been working on this car to long. Lifted up and gearbox out in 58 minutes.

Will get the driveshaft away for shortening next week and figure out the rest.
58 mins - with an F1 pit crew on hand per chance :nailbiting:

I sense a challenge coming on…instead of a power board a ‘Zorg who can strip a Z3 fastest board’ :whistle:
 

Dino D

Zorg Guru (V)
British Zeds
Joined
Mar 28, 2014
Points
176
Location
Kent
Model of Z
2.8 Manual
Not sure if I already mentioned these guys to you

Made here and reasonable price too as you buying direct. Seem very knowledgeable when I spoke to them and helpful when I had to swap the kits as the 5sp was different to the 6sp.
Been fine on mine but I’m probably only 220bhpnand only driven a bout 5 tanks of fuel on it!
(Single mass but same weight as stock - they don’t like supplying lightweight for this drivetrain -some about too much shock then going on through the diff etc)
 

Delk

Zorg Guru (III)
British Zeds
Joined
Oct 9, 2018
Points
125
Location
Hemsby Norfolk
Model of Z
Z3 2.8 real widebody
I have a twin disc clutch supplied by Hopwood motorsports. It's a mix of parts since the 6 speed has a larger input shaft.

The DKM one I had was uprated but not up to the power level I'm running. It survived awhile but is completely toast now. Never liked it as rhe pedal pressure was very high so I won't miss it.
 

Delk

Zorg Guru (III)
British Zeds
Joined
Oct 9, 2018
Points
125
Location
Hemsby Norfolk
Model of Z
Z3 2.8 real widebody
Dropped off the driveshaft to be shortened.

Installed clutch and put gearbox in. The M3 six speed is much heavier then the original box. Not sure how much but it was noticeable wrestling it in.

Just need to shorten the shift linkage and get my driveshaft back.
 

Delk

Zorg Guru (III)
British Zeds
Joined
Oct 9, 2018
Points
125
Location
Hemsby Norfolk
Model of Z
Z3 2.8 real widebody
Had a slight delay but the car is back on the road.

Shop that shortened the drive shaft separated it for shipping without marking it. So I had to send it back for balancing again.

New twin disc clutch is fantastic with a standard peddle feel. After years on the heavy clutch its a pleasure to drive again.
 

t-tony

Zorg Expert (II)
Supporter
British Zeds
#ZedShed
Joined
Dec 31, 2013
Points
226
Location
Torksey Lock,Lincoln, England
Model of Z
E89 Z4 23i Auto
I had similar problem with an MG Metro turbo, not the standard factory turbo either. Someone had fitted a Turbo Technics kit before I bought it. The Turbo sat where the original had the carburetor , which in turn was mounted round the end of the engine on an alloy housing. It was stupidly quick but ate clutches.

Tony.
 

Ausz3

Newbie
Joined
Sep 19, 2022
Points
3
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 wheels and specs mate ? I also have a 2.8 Frankenstein turbo in Australia though
 

Delk

Zorg Guru (III)
British Zeds
Joined
Oct 9, 2018
Points
125
Location
Hemsby Norfolk
Model of Z
Z3 2.8 real widebody
I have 2Forge ZF6 wheels in gunmetal grey to suit the car.

Rears are 18x10 with 295 wide Pilot Sports,
Fronts are 18x8 with 245 wide pilot sports.
Everything fits well and I dont have any rubbing.
I used Z4 hubs in the rear to narrow it by 22mm each side. This allowed better wheel fitment and I could also run 328i rear brakes with a bit of modification for the caliper mounting. The 328i disc is vented and fit perfect with the hubs.
 

Ausz3

Newbie
Joined
Sep 19, 2022
Points
3
I have 2Forge ZF6 wheels in gunmetal grey to suit the car.

Rears are 18x10 with 295 wide Pilot Sports,
Fronts are 18x8 with 245 wide pilot sports.
Everything fits well and I dont have any rubbing.
I used Z4 hubs in the rear to narrow it by 22mm each side. This allowed better wheel fitment and I could also run 328i rear brakes with a bit of modification for the caliper mounting. The 328i disc is vented and fit perfect with the hubs.
Thanks mate I'm also running the z4 hubs do you know the wheel offsets ?
 

Delk

Zorg Guru (III)
British Zeds
Joined
Oct 9, 2018
Points
125
Location
Hemsby Norfolk
Model of Z
Z3 2.8 real widebody
Thanks mate I'm also running the z4 hubs do you know the wheel offsets ?
I had a look and couldn't find what I ordered. I think the front was about max so ET50. Rears were less around ET35 but thats just a guess.
 

Ausz3

Newbie
Joined
Sep 19, 2022
Points
3
I had a look and couldn't find what I ordered. I think the front was about max so ET50. Rears were less around ET35 but thats just a guess.
No worries mate thanks for the info if you ever remove the back rim have a check for us should be stamped someone on the back of rim 👍 . How is the car driving lately ?
 

Delk

Zorg Guru (III)
British Zeds
Joined
Oct 9, 2018
Points
125
Location
Hemsby Norfolk
Model of Z
Z3 2.8 real widebody
Been awhile since I updated this.

Car is still running great. About the only recent change I made was to the back box and going back to a twin tip exhaust on one side compared to the fabricated quad tip M copy. Still a bit louder then I would like but it is what it is to get the flow.

I am collecting parts to build the next engine so I can increase the power safely. I have had trouble getting items as half the people making aftermarket parts are on seriously long back order. Most of the modifications to turbo the car will remain the same such as the stand alone ECU fueling and other items. I am just focusing on the engine itself.

Next engine
M54b30, picked up a really clean used engine that is in great shape.
Eagle H beam connecting rods
Wiseco 9.0 compression forged pistons
ARP 11mm head studs for the S54. Will also machine the block for thread inserts so they dont pull out of the aluminum.
Garrett G30-770 turbo. Currently have a Holset HX35 that works well but is very old technology. The new one will flow and spool better.
Oil pump upgrade with better fixing of drive gear and chain tensioner so the nut doesn't fall off.
VAC front vibration damper

Currently I am looking to get an aluminum intake manifold set up for boost with the forward facing throttle body. There are a few for the M52 available but any for the M54 are on backorder for at least another month. I dont want to modify the head to take the M52 unit and would rather get the correct fitting one. This will eliminate the disa valve and allow me to run much higher boost without concerns of leaks or a broken manifold.

I am also debating to convert the car to drive by wire or stick with a cable operated throttle body. I have the correct throttle peddle assembly and everything to convert it but not sure the gains if any are worth it. I need to talk to the tuning shop again and if my ECU will support boost control by speed this maybe worth while.
 

deano1712

Zorg Legend
Joined
Jan 2, 2012
Points
74
Location
Leeds
Model of Z
Z3M
Just read through your thread looks like a nice job, well done. I may make zedfest so will look out for the car. I did a similarly crazy job on mine many years ago and know the journey takes time to iron out all the issues.
 

Delk

Zorg Guru (III)
British Zeds
Joined
Oct 9, 2018
Points
125
Location
Hemsby Norfolk
Model of Z
Z3 2.8 real widebody
Collecting the last bits to finish off before fitting the new engine this winter.
Just ordered a Bosch 82mm drive by wire throttle body. Already picked up an electric pedal assembly so I'm all set. This will eliminate the idle control valve and make tuning easier.
Hope to get the engine fitted in January and if I get it running tunes sometime early in the year.
Work is always busy over the winter so this slows things down.
 

Stevo7682

Zorg Expert (I)
Supporter
The M44 Massive
Scottish Zeds
Joined
Apr 1, 2016
Points
208
Location
Maybole , South Ayrshire
Model of Z
Z3 Individual Dakar / Orinoco Individual
We'll be coming down to Caister next July Delk so hopefully looking forward to getting an opportunity to see the next stage of your zed .
Got to say was highly impressed with the 2.8 turbo set up you currently have fitted
Stephen.
 

Delk

Zorg Guru (III)
British Zeds
Joined
Oct 9, 2018
Points
125
Location
Hemsby Norfolk
Model of Z
Z3 2.8 real widebody
Progress with engine MK2 has been moving but slowly because family, work and life.


Engine is built and now collecting all the extras. Not much will remain of the first version except the exhaust, turbo manifold and ECU.

Changing to drive by wire to get rid of the idle control valve. It will also have some tuning benefits.
New intake fitted, will require relocating the power steering reservoir.
Will reuse the same turbo manifold but with a new Garrett G30 turbo mounted on it.
850cc injectors should be arriving this week.

Made a new bracket to fit B58 ignition coils for more spark. Will finish the wiring loom shortly.

Modified a fuel hanger with a larger pump so will need plumb all that in.



I have family coming over from the States for Christmas so not sure if I will get it installed then or not. Work is going to have me busy through April and I will be away quite a bit. Would be nice to get it in and running so I can find all the small things that need ordering.
 

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