BMW 2002 Homemade Turbo Build Thread
 

I finally parked my car last night for a while, while I turbocharge it and convert it to megasquirt fuel injection. I figured that there are people out there who own these cars and want to gain more performance out of them, but aren't exactly sure where to start - so that's why I'm making this thread, it's from start to finish, a complete build thread that covers the removal of every nut/bolt, the splicing of every wire, etc - the only thing I will not cover is intercooler mounting in here, since I did that without taking pictures and it will vary greatly from car to car, but standard turbocharger placement and FI conversion should take care almost all of the guesswork out of this project.

This endeavor is being undertaken upon by my 1976 2002. It has a rebuilt engine with 20K on it, it could definitely use a lot more power, so FI (both fuel injection and forced induction haha) are going to be installed on this car.

As it stands, the car has a 32/36 carb, upgraded ignition system, a few other tidbits among the engine bay, but it should be almost identical to most other 2002's out there.

Here's a rough sketch of a parts list, including what I have so far and what I'm still waiting on or haven't ordered.

http://img504.imageshack.us/img504/8...rtslistbs1.png

The plan:
20PSI on this car running Megasquirt-II fuel/spark management with american car parts thrown in. Will be hooked up to a laptop and monitored via MS interface, which will give readouts to all major components of this system.

Current compressor map showing engine specs and variables:
http://img389.imageshack.us/img389/2917/t04mapfl8.png



Note, I have not decided yet on a BOV/boost controller, those are not in the parts list yet.

So let's get started, this will be updated as I work on my car on a daily basis, sometimes less frequently but we'll see how everything goes.

First things first, disconnect the throttle linkage bracket from the firewall. This is held in by two 12mm bolts. Slide the bracket upwards over the shaft that connects to the carburetor, this will seperate the carburetor from the plate.
https://farm4.static.flickr.com/3097...4f036c82_o.jpg

Remove the carburetor top plate as it makes it easier to remove work with, it's held on by four 10mm bolts.
https://farm4.static.flickr.com/3025...345bd437_o.jpg

Use a flat head screwdriver to loosen the clamps on the fuel lines on the pump, and the carburetor. Remove the lines, leave the inlet line (with filter) in the car, as well as the return line coming off the caburetor.
https://farm4.static.flickr.com/3143...9989d526_o.jpg


Disconnect the brake booster line from the valve cover. Mine was pretty gunked up on the inside leading me to believe the motor was sludging, but when I pulled the cover off it was a different story.
https://farm4.static.flickr.com/3184...31f876d4_o.jpg

Remove the two 12mm nuts on the fuel pump base.
https://farm4.static.flickr.com/3278...6b1e946a_o.jpg

A block-off plate will need to be fabricated/installed here, simple task - requires a bandsaw/cutter & drill.
https://farm4.static.flickr.com/3091...b3cdf7f4_o.jpg

Remove the 4 12mm nuts on the base of the carburetor (this is for a Weber 32/36). The carburetor will slide over the studs revealing the manifold & carb gasket/spacer. The fluid between the runners on cylinders 3 and 4 is just fuel that spilled out of the pump.
https://farm4.static.flickr.com/3009...b6184f91_o.jpg

The inside of my manifold still looks pretty clean - it has to be scrapped however for an M10 318i intake manifold.
https://farm3.static.flickr.com/2369...5f23115f_o.jpg

Carburetor is in great shape still minus the gunk, I'll clean it off and sell it since it was rebuilt ~500 miles ago.
https://farm4.static.flickr.com/3141...61f20452_o.jpg
https://farm4.static.flickr.com/3025...f56bb637_o.jpg

I started removing the top nuts on the manifold, they were 12mm - but I gave up when I realized that the bottom ones are damn near impossible to remove without getting the head off, so I'll just take the manifold off with the head. Meanwhile, remove the eight 10mm nuts that hold the valve cover on.
https://farm4.static.flickr.com/3149...165497c0_o.jpg

Break time. Greg's E30 is prowling in the back.
https://farm4.static.flickr.com/3095...84655e17_o.jpg
https://farm4.static.flickr.com/3265...2cf160c0_o.jpg

With the valve cover off, you can gain acess to the head bolts. They are 19mm bolts and there are 8 of them. Take them off in sequence, start with the corners and go towards the inside, gradually loosening up each bolt 1/4th to 1/2 turn at a time until they're loose and can be removed by hand.
https://farm4.static.flickr.com/3098...32454a4f_o.jpg

It may be hard to break them at first, you can use 2 wrenches together to substitute as a breaker bar if you're too lazy to walk to the table and grab one.
https://farm4.static.flickr.com/3119...21eba325_o.jpg

My valve cover still looks pretty good, there's no sludge at all.
https://farm4.static.flickr.com/3029...eee29645_o.jpg

It helps to organize all your parts in bags.
https://farm4.static.flickr.com/3082...59b2222c_o.jpg

Remove the coolant lines, remove any and all coolant lines that go to/from the head. The line from the temp sensor housing to the manifold can remain as it will come off with the head and can be disconnected at a later time.
https://farm4.static.flickr.com/3081...967b4c95_o.jpg

Remove the bracket that holds the coil in place, it is held on by one 10mm bolt. Unplug the coil and remove it.
https://farm4.static.flickr.com/3111...c26ec6d0_o.jpg

Remove the three 13mm (IIRC) bolts on the side of the distributor, towards the firewall. The bottom one is the hardest to get to. Remove the distributor cap if you need room for your hands. Unplug all plug wires and remove them from the vehicle. This exposes your distributor gear.
https://farm4.static.flickr.com/3062...8c5060ea_o.jpg

With the head bolts removed, the head is almost ready to be removed.
https://farm4.static.flickr.com/3257...be74353a_o.jpg

I'm stopping here, will continue tomorrow.

Re: BMW 2002 Homemade Turbo Build Thread
 

very nice

now post some porn

Re: BMW 2002 Homemade Turbo Build Thread
 

sick ------' project.

Re: BMW 2002 Homemade Turbo Build Thread
 

Remove the eight 10mm bolts on the side of the timing chain cover.

https://farm4.static.flickr.com/3166...79973bbc_o.jpg
https://farm4.static.flickr.com/3015...800d0657_o.jpg


Remove the 10mm bolt that holds the dipstick bracket on the driver's side of the manifold.
https://farm4.static.flickr.com/3259...196e436d_o.jpg

Remove the bolt that attaches the alternator ground to the timing chain cover.
https://farm4.static.flickr.com/3277...5a21e83f_o.jpg

Insert a prying tool in as shown.
https://farm4.static.flickr.com/3090...7cf5c852_o.jpg

Gently pull towards the front of the engine, the cover should seperate.
https://farm4.static.flickr.com/3118...35465755_o.jpg

Flatten the tabs that lock the cam bolts in place.
https://farm4.static.flickr.com/3056...01505527_o.jpg
https://farm4.static.flickr.com/3023...a748988e_o.jpg

Clean the sprocket and chain off with a cloth and make marks to line up when reinstalling the cam.
https://farm4.static.flickr.com/3017...b0af0023_o.jpg

Gently pry the sprocket off from the back, from multiple directions.
https://farm4.static.flickr.com/3260...6e9563ee_o.jpg

Lower the sprocket within the chain, and remove it once the teeth slip off of the links.
https://farm4.static.flickr.com/3099...e7caac1f_o.jpg

Secure the chain with a coat hanger or whatever. I found a coathanger laying around so I used that.
https://farm4.static.flickr.com/3006...e6fc2dd9_o.jpg

That's all I had time for today, I stayed late from work and had to stop working on the car early and go see Hancock with some friends. Great movie by the way.

Re: BMW 2002 Homemade Turbo Build Thread
 

that carb is a weber 32/36. you can get a holley 500 adapter plate.. i'd highly advise it, the weber flows enough air for a n/a toyota pickup, i can't imagine a bmw with boost.

wait, it's a 4cyl, not a 6. 6's had dual webers, the jetting is plug and play for a 22r swap. eh still, a nice fat holley would make for easier tuning and such

Re: BMW 2002 Homemade Turbo Build Thread
 

awesome project ;D

Re: BMW 2002 Homemade Turbo Build Thread
 

lol im pretty sure he is going to be running fuel injection bob

Re: BMW 2002 Homemade Turbo Build Thread
 

Spot on, Megasquirt V3 will be the parts controller, I'll be using GM coils, custom coil mounts (you'll see them when I get to them, attached to the valve cover), and a custom tune when this is done.

Re: BMW 2002 Homemade Turbo Build Thread
 

That FMIC looks like it means buisness

Re: BMW 2002 Homemade Turbo Build Thread
 

Car looks good, keep up the good work!!

Re: BMW 2002 Homemade Turbo Build Thread
 

sweet build :6

Re: BMW 2002 Homemade Turbo Build Thread
 

Got a few parts in today, closer and closer every day :P

Megasquirt V3.0
http://img510.imageshack.us/img510/4377/s6302277ux0.jpg

A little something to help with cooling
http://img112.imageshack.us/img112/1610/s6302279pp4.jpg

Sum gauges and ---- yo.
http://img57.imageshack.us/img57/3075/s6302280cl7.jpg

Walbro :P
http://img57.imageshack.us/img57/5051/s6302281sz0.jpg

ARP goodies
http://img79.imageshack.us/img79/750/s6302282gp5.jpg

XS BOV
http://img68.imageshack.us/img68/5148/s6302284vf8.jpg

Re: BMW 2002 Homemade Turbo Build Thread
 

i hope you didnt let your chain drop into the cover. have fun when the chain binds itself

Re: BMW 2002 Homemade Turbo Build Thread
 

Already posted but

https://farm4.static.flickr.com/3006...e6fc2dd9_o.jpg

Being held up by a coathanger.

Re: BMW 2002 Homemade Turbo Build Thread
 

ought to be interesting!

Re: BMW 2002 Homemade Turbo Build Thread
 

hurry up and finish this ----. I wanna see how it turns out. 8)

Re: BMW 2002 Homemade Turbo Build Thread
 

ETA of videos of the car coming on or around July 25th.

HOPEFULLY.
:P

Re: BMW 2002 Homemade Turbo Build Thread
 

Sorry for the lack of updates - been busy with work and ----. No pictures today.

Here's where I'm at in terms of fab so far:

Flipped the exhaust manifold upside down, fabbed up an adapter to mate the exhaust flange off the manifold with a new inlet flange I made myself for the turbine - none of it is pretty, there's some cleanup, but the welds look to be rock solid and should hold quite a bit of pressure.

Still waiting on IC piping, injectors, fuel rail, etc - this thursday I should have all the fab work done. Gotta make an intake manifold, gonna buy some aluminum welding rods tomorrow and start fabbing up the plenum & runners. Also need to buy some aluminum pipe... Note to self lol.

And you guys will get a kick out of what I'm using to make the plenum for the intake manifold :P

No secrets revealed yet, just know it's a large part of the car that I removed at one point and it's... roughly, the perfect size and shape for a decent plenum with little fab work needed.


Pics and updates coming tomorrow.

Re: BMW 2002 Homemade Turbo Build Thread
 

Turbo mounted on head.
http://img509.imageshack.us/img509/2568/s6302294as1.jpg

Here's the adapter I made for the flipped manifold to the turbo - the welds look like crap but they're rock solid, a little grinding and finishing and it'll look pretty.
http://img231.imageshack.us/img231/57/s6302295zm1.jpg

And here's the piece de resistance, the bumpermanifold.

This is just the plenum right now, sending it out to get welded soon - then fabbing up my own intake mani to head flanges and getting that welded.

http://img231.imageshack.us/img231/7720/s6302299xn3.jpg

Intercooler piping also came in yesterday, gotta take a sawzall to the front of the car and start routing ----.

Re: BMW 2002 Homemade Turbo Build Thread
 

BDVT said someone needed a intake mani welded, assuming this is you? I have welder :y

Re: BMW 2002 Homemade Turbo Build Thread
 

damn, so far this is the most deserving write-up for the write-up contest. i hope it finishes as well as it started

Re: BMW 2002 Homemade Turbo Build Thread
 

What's your location?

Re: BMW 2002 Homemade Turbo Build Thread
 

20 mins north of seattle.

Re: BMW 2002 Homemade Turbo Build Thread
 

Are you available next week, tuesday or wednesday afternoon?

Re: BMW 2002 Homemade Turbo Build Thread
 

Thats whom I was going to have you hook up with anyways!

Re: BMW 2002 Homemade Turbo Build Thread
 

sweet project man, been thinkin of picking one of these up myself to do the same thing!

cant wait to see it rolling. what kinda power you shooting for?

Re: BMW 2002 Homemade Turbo Build Thread
 

Whatever 21psi with water sprayers on the IC will give me. I'll take it to a dyno day shortly after the tuning is done.

Re: BMW 2002 Homemade Turbo Build Thread
 

Available anytime basically, not working right now.

Re: BMW 2002 Homemade Turbo Build Thread
 

Great - you should PM me your number (with your name lol so I don't sound dumb when I call or text ya).

Contributing to post:

Did more flange and manifold work today.

Master welder at work.
http://img241.imageshack.us/img241/2339/s6302303te3.jpg

I cut the original manifold for the flange, will bore the diameter out though.
http://img237.imageshack.us/img237/3499/s6302306zm4.jpg
http://img154.imageshack.us/img154/7237/s6302312ov1.jpg

Then got to work on the wastegate blockoff valve and 3" DP flange. This was just simple cutting and welding of existing exhaust and turbo manifold pieces I already had.
http://img154.imageshack.us/img154/2686/s6302314ar7.jpg

Then I cut aluminum pipe at a 7.5 degree angle for the runners, the top is flat but will be angled later for welding to the plenum.
http://img154.imageshack.us/img154/4811/s6302315vb6.jpg
http://img401.imageshack.us/img401/4285/s6302316nq7.jpg

I ditched the ITB idea as it would be too time consuming, individual runners will do fine. Tomorrow I'll finish up cutting the runners to the correct angles and then prep everything for TIG welding - at which point the intake mani will be done, with the exception of fuel injector bungs (still waiting on those to arrive) and vacuum nipples.

Re: BMW 2002 Homemade Turbo Build Thread
 

throttles are more of a pain than they are worth unless you really have a built up NA motor that is getting restricted by the intake. did em on my rabbit w/ a 16v an they were fun, but it took way more effort than normal to get the car tuned to run well

Re: BMW 2002 Homemade Turbo Build Thread
 

Removed the battery tray, as it was shitty and plastic and broken.
http://img187.imageshack.us/img187/2089/s6302319uf4.jpg

Lubed and installed ARP studs into the block (will clean pistons before reassembly, I PROMISE)
http://img187.imageshack.us/img187/7458/s6302321tk4.jpg

Threw the head on using the old gasket to avoid scratching surfaces, then bolted the manifold on
http://img183.imageshack.us/img183/1567/s6302322ke8.jpg

Installed the manifold to turbo flange, test mounted the turbo - sits too close to the radiator.
http://img294.imageshack.us/img294/4840/s6302324ey0.jpg

Took a sawzall to all that stood in my way.
http://img185.imageshack.us/img185/6758/s6302325ru5.jpg

Radiator was in the way, remove the 4x12mm bolts on the back of it in front of the engine to remove it. Unhook all the coolant hoses before doing so to avoid damaging them if you plan on reusing them. My hoses are still new and good so I'm keeping them.
http://img294.imageshack.us/img294/9858/s6302326iv1.jpg

Remove the 4x10mm bolts on the front of the water pump pulley to remove the fan, giving you more room to work.
http://img520.imageshack.us/img520/134/s6302327cp7.jpg

That's all I've done so far, still waiting on all the parts to arrive -next week will be a big week as everything will be coming together, so the writeup should gain some ground and get a lot more accomplished once everything is in and I'm assembling it.

Re: BMW 2002 Homemade Turbo Build Thread
 

Not a bad update; keep up the good work.

Re: BMW 2002 Homemade Turbo Build Thread
 

I found a panel off of a copy machine I decided would make a good switchboard. I drilled four random holes (didn't measure, didn't care) that looked about right to install switches to. One switch for the fuel pump, one switch for the gauges, one switch for the megasquirt unit, and one switch for the intercooler sprayers.

http://img134.imageshack.us/img134/9673/s6302329nu0.jpg
http://img134.imageshack.us/img134/7207/s6302330ia8.jpg


Drilled a hole in the trunk to route the battery cable through.
http://img380.imageshack.us/img380/9046/s6302332qp7.jpg
http://img134.imageshack.us/img134/5412/s6302333vu7.jpg

Then two more holes right above the passenger footwell for entry into the engine bay.
http://img134.imageshack.us/img134/60/s6302334ap1.jpg

Two more holes through the body where the IC piping will go, this makes it easier to start the sawzall through it.
http://img134.imageshack.us/img134/1343/s6302335mk0.jpg
http://img134.imageshack.us/img134/4828/s6302336rg1.jpg

Routed the primary wire through the firewall.
http://img517.imageshack.us/img517/2573/s6302337mi4.jpg

Then looped both up through the dashboard to power the switches.
http://img380.imageshack.us/img380/7826/s6302338ew5.jpg

Then mounted the copy machine switchboard panel with clearly visible inline fuses in the dashboard.
http://img380.imageshack.us/img380/5007/s6302339mb7.jpg

More coming tomorrow.

Re: BMW 2002 Homemade Turbo Build Thread
 

"Tomorrow" was a week ago - still no update. Did it blow up? If so, post the ripper vids. :1

I was working on putting a Ford 2.3T in an E21... kinda stalled out on that project about a year ago - it's still sitting here, I just need to build some mounts and install/wire an engine. :6

http://homepage.mac.com/limefrog/con...7-Images/4.jpg

http://homepage.mac.com/limefrog/con...7-Images/1.jpg

Colin

Re: BMW 2002 Homemade Turbo Build Thread
 

Lol something interesting happened. I'm still tinkering with it but I took a break. I'm preoccupied this whole weekend with another car that needs to be done ASAP. The 2002 will get all the loving it needs soon, but I'm concerned with trying to make some extra money this week since my birthday is next Monday (18th, turning 20). Recent updates include, head came back from being cleaned and resurfaced and pressure checked, crank pulley with attached trigger wheel came in, the rest of my hoses/couplers, just waiting for some spare time to finish this thing - but the concept of making extra money by working on another car is just too damn appealing. Especially since that other money can go into making this thing more awesome than it is :D

To my faithful readers, soon - patience.

Re: BMW 2002 Homemade Turbo Build Thread
 

Where are the pic's :6

Re: BMW 2002 Homemade Turbo Build Thread
 

Here's all you guys will get this whole week - I'm busy with an STI for a few days so until then the 2002 is on hold, this weekend all work on the car begins.

For now, here's a 100% complete 2002 turbo kit sitting on a table, a few pieces are not on the table as they are in the car but - yeah, you get the paint:

http://img247.imageshack.us/img247/9...60largera4.jpg

Re: BMW 2002 Homemade Turbo Build Thread
 

Threw the sprocket on to align the cam to tdc.

http://img95.imageshack.us/img95/7103/s6302367hg7.jpg
http://img530.imageshack.us/img530/1037/s6302368cp3.jpg

Crank pulley TDC with the 36-1 EDIS wheel.
http://img230.imageshack.us/img230/1949/s6302369lm6.jpg

MLS headgasket placed on block, had to remove the coathanger from the timing chain and then reattach it to keep it upright.
http://img230.imageshack.us/img230/5536/s6302370ms6.jpg

Placed the head over the studs and lowered it on top of the HG.
http://img291.imageshack.us/img291/6425/s6302371pi0.jpg

With cylinder #1 at TDC, the cam sprocket had to be aligned so the hole (seen in picture pointing to the bottom of the motor) with the stud on it can align with the cam sprocket holder. If it's not aligned, skip a tooth on one end of the chain in the direction you need to rotate it and lead the chain all the way around the sprocket until the sprocket lines up with the cam holder.
http://img291.imageshack.us/img291/6672/s6302372ik2.jpg

To get the chain to have enough distance to throw the sprocket on, the head must be tightened down just a bit to compress the MLS gasket (not torque it), do it in sequence, start from the middle and work your way out just a bit.
http://img503.imageshack.us/img503/7388/s6302373fn9.jpg

Compress the timing chain tensioner on the top of the timing chain lower cover (passenger side) inwards to give the chain enough slack to where the sprocket will line up and bolt up. There are 4x10mm bolts that you need to tighten on it.
http://img244.imageshack.us/img244/4633/s6302374jg7.jpg

Attach the oil sprayer for the cam lobes.
http://img210.imageshack.us/img210/6960/s6302375ok7.jpg

The head is now installed and ready to be torqued down. I threw the intake manifold on so I could begin aligning stuff and getting ready to do the IC piping.
http://img225.imageshack.us/img225/1558/s6302376bi1.jpg

Re: BMW 2002 Homemade Turbo Build Thread
 

its so frustrating seeing closed decks lately. i wish honda would do this

http://img187.imageshack.us/img187/7458/s6302321tk4.jpg

Re: BMW 2002 Homemade Turbo Build Thread
 

Yeah i wish the same dam honda for not doing that way