BMW 1602 -67 M20B25 Turbo 525whp

[oskarkronlid]

I've been working on my 02 for the last 4,5 years and now its finaly fired upp.

Engine: M20B25

Forged pistons and conrods

MLS head gasket

Welded head with Z45 turbo camshaft

Upprated springs, valves, and rockers

Vi-pec ECU

Precision Sc62 Turbo

Aiming at över 500 hp on the wheels

[oz_tom]

Awesome.

What gearbox, diff and drive shafts are you using?

[Guest]

Nice! Post up some pics!

A few questions, what did you weld on the head? Why not go with adjustable coilovers and increased negative camber after all that work to tube-frame the front of the car? I'd also like to know what you using for the diff, axles, and rear suspension.

[Derek]

Please:

Share build info and pictures. Very nice work.

[Lorin]

Bad ass. I really like the evil smoke curling out from under the intake manifold.

[rover1]

bad ass!!!

[oskarkronlid]

I will now tell you the background story.

If I write kind of funny it's because I'm from Sweden

My BMW fascination started with my first BMW

A -98 that I bought -01

M Roadster 3.2l 321hp

It was a really fast car. The most impressive car I had driven before that was my mother’s Toyota Camry V6 so this was a step up

I also needed something to drive in the winter so I bought an E36 325 Coupe. Also a nice car.

In 2004 we built our new home so I needed some cash.

I sold both cars, but I still needed at least one car so we bought something more practical. An Audi S4 -99 Bi-Turbo 310hp 4WD, It needed constant repairs all he time

The S4 had to leave us and was replaced by a Volvo V70 not fun but cheap and practical.

But after a while I felt a need for something a bit more fun.

I found this 1600-2 -67

After some work

After a while I realized that if I ever wanted to drive I needed something a bit more finished so I sold the body stripped of everything that I had restored and bought this instead

It was just a rolling chassis

As I had already restored the struts on my old car I replaced the ones on the new car

Old struts

My restored struts with Bilstein shock absorbers (Newly produced from the specifications of the old 02 racing series in Sweden ) & H&R springs. Volvo 240 calipers, vented discs and hub from e21

Did not like the hight even though the springs were supposed to lower the car 40 mm.

I decided to use the old shorter springs. They were so short that they fell out when I lifted the car so I welded a piece of pipe to hold them in place.

End result

That’s the right hight

Building the rear end.

Removed the welded diff

Replaced it with a LSD from 320is

And combined driveshafts from e21 with 02 outer flanges to make them fit.

We will see for how long it lasts

Mounted

Anti roll bars from Ireland Engineering

Some speed parts arrived from PPF

Precision SC62

and a Tial 38 wastegate

I've modified the oil pan with a hose connection for oil return from the turbo, and an oil level plug since the side where the dipstick should go has been cut off to make the engine sit low in the car.

Painting some parts

Earlier I've painted some parts in Laguna Seca since my original plan was to paint the car in this color.

Test mounting the turbo to see where to weld the wastegate

Engine parts painted and assembly begins

Engine looking good

My daughter helping out

Bought a Nuke fuel rail from PPF and used injectors from Avvah

Started by cutting in my newly painted intake manifold

Made some brackets for the fuel rail

The new "Blackline" series

Improved ceramic clutch, 618 pressure plate form Sachs capable of 700nm

Mounted the engine in the car

Threw out the exhaust manifold from kina and replaced it with a high quality exhaust manifold from PPF heat coated

Made a boot floor out of aluminum and started laying out the fuel system

Aeromotive Eliminator capable of 700hp on ethanol

New exhaust in place

Also got myself a blingbling alternator

Mounted PPF fuel filter

I placed the fuel cell a little higher than the fuel pump so it doesn’t suck air.

Brackets for intercooler and radiator

Built some pressurepipes and downpipe

Brackets, pipes and hoses for the brakes

I have two sets of wheels, can't decide which to use

White 17"x7.5"

or 16"x9"

I bought a very nice exhaust manifold form PPF but I decided to go for a bigger wastegate, a 46mm Precision so I had to make some modifications

Connected some instruments

And now the engine has been started

Still some things to do before it’s on the road. I'll keep you posted.

[Guest]

I vote for the 16x9's.

About the diff, that e21 will last you about a day at 500whp. My friends blew up an open e30 small case(same size) in a week at ~350whp. I know how much it sucks to keep putting a project off, but considering how heavily modified your car is already, sell the e21 diff and get an e30 rear end with medium case diff. Swap that whole setup in(trailing arms, subframe, diff), it's not bolt on but it should handle the power for a while at least. 500whp is getting mighty close to large case diff territory.

[oskarkronlid]

You are probably right but I will see what breaks first.

I still have the welded diff sitting in my garage so that is always a temporary solution if the 320is diff breaks. And an extra gearbox.

The plan is to swap the entire rear subframe and diff to the one from Z3M or a M535 diff with "sviktstål" axels. I don't know what its called in English

but direct translation would be flexsteel. Its axels that’s capable of twisting 1.5 laps and flex back without breaking. It really saves the rest of the drivetrain.

And a gearbox from a 5 or 3 series tds then it's good for at least 800 hp.

But that will have to be next winters project...I hope ;-)

[jrkoupe]

16 x 9s all the way.....hands down.

w/ such a short frt spring wont you bottom out your shocks over and over?.

[oskarkronlid]

I'm not sure, the shocks are shortend and hard as rock compared to original but if it's undrivable I'll replace it with the longer H&R springs. I saved them just in case.

[2002haus]

What a great build - keep up the good work!

[oskarkronlid]

Now I've been at PPF in Avesta Sweden. The engine has been tuned by Andreas at PPF. The car was placed in the Dynapack to see how much power I have on the wheels.

Result: 525whp and 686nm of torque (505lb-ft) approximately 600hp at the crank.

Thick lines are at 1.5bar (21,76psi) of boost and the thinner lines at 1 bar (14,50psi) of boost

[roadhog0]

Holy Cow!!! That is a LOT of power in a car that weighs that little! Very sweet car man!!

[ray_]

Amazing build! Keep us updated!

Personally I think 500hp in an '02 may be rather dangerous. But maybe I'm just getting old. :-) Please be careful with it!

Cheers,

Ray