BMW E23 745i Turbo - The four door six! (Picture heavy..)

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///Moe
Posts: 284
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Location: Norway
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BMW E23 745i Turbo - The four door six! (Picture heavy..)

Post by ///Moe »

This thread will be about my BMW E23 745i Turbo. :-)
I know it's not a six, but as a relative it should appeal to most of you.
It's originally a 1982 with the M102 3,2l L-Jetronic turbo engine which once had a 3-speed automatic transmission.
No 745i's were sold new with manual transmission except for a few but they are extremely rare. I once converted this car into a 4-speed manual but after less than a week I swapped it with a 5-speed Getrag 265 (as it has now) instead. I also have a 25% LSD lying around, 210mm / 3.07 which is same as the original except it's an LSD unit. Overall the car is quite rusty underneath and there are lots of imperfections, but from a distance it's a cool car. I have owned it for more than six years now (bought it in 2006) and it was my first car once I got my drivers licence. Althought it was my first car I have NEVER been off road with it, and I haven't exactly been gentle behind the wheel.. I ran this car for a couple of years with a little bit more than 1,0 bar boost vs 0,5-0,6 bar which it had originally, until a worn piston rod began knocking. And that's where this project once started..

The engine has now been completely overhauled with every single bearings, gaskets, piston rings, timing chain, oilpump, rocker arm shafts, bits and bolts ++ brand new! Basically it's only the block, crankshaft and pistons that are still being used from the "old" engine, everything else inside is either upgraded or bought new. I have barely cheaped out on anything with this build. (focusing on the engine, to begin with)

Upgrades:
-Stronger valve springs + retainers. (capable of 8500rpm / 13mm lift)
-Reinforced rocker arms.
-Rocker arm locks (Instead of springs)
-Steeper camshaft (284 degree / 11,2mm lift)
-MLS headgasket. (I didn't use this..)
-Precision 6265 T4 / V-band .81 A/R turbo
-External 50mm, adjustable wastegate.
-Reinforced piston rods (H-profile)
-ARP bolts for both top and bottom.
-M106 oil spray nozzles (Retrofitted)
-Getrag 265 manual transmission (Instead of automatic)
-Sachs 765 heavy duty pressureplate. (stronger)
-6-puck sinter clutch / lamell.
-Vipec V44 fully programmable engine management.
-750cc flowmatched fuel injectors. (these will be replaced with bigger one's)
-Two 044 fuelpumps.
-Adjustable fuelpressure regulator.
-Innovate LC-1 wideband lambda.
-Newer idlecontrol solenoid.
-TPS with 0-5v signal.
-Triggersensors.
-Triggerwheel from E34 (60-2)
-Bigger intercooler.
-Motronic timing chain cover.
-NGK BP7ES sparkplugs.
-Bosch coilpack, for wastedspark ignition.
-Homemade turbo exhaust header.
-Various exhaust parts (homemade exhaust system)


OEM parts:
-Machined crankshaft (since knocking)
-3,2 Turbo headgasket (original M102)
-Complete gasketset for the engine, new seals etc.
-Complete new timing chain / sprocket kit.
-New rails + chain tensioner for the chain.
-New rockerarm shafts.
-New oilpipe for the cylinderhead.
-New rod and crankshaft bearings.
-New rodbolts for the pistons.
-New piston rings.
-New oilpump.
-New waterpump.
-New transmission crossmember + mounts.
-New viscous and fanblade.
-New coolant hoses.
-New 745i radiator and heater core.
-Various nuts and bolts.


What the car looks like today:
Image

Image
Last edited by ///Moe on Wed Jan 21, 2015 3:49 pm, edited 4 times in total.
E24 635CSiA 85' (garage queen)
E24 628CSiA 83' (turbo/manual?)
E23 745i 82' (turbo project)
E23 728i 86' (745i project)
E23 728i 79' (part's car) [x]
E28 525i 81' (part's car) [x]
///Moe
Posts: 284
Joined: Sun Jan 15, 2012 8:10 pm
Location: Norway
Contact:

Post by ///Moe »

The car is up and running now but I'll follow you up with pictures from the build process before I release the "finished result" and continuation.

First out, a photo of what I had to start with:
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And what I ended up with.. (not finished here)
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Some of the parts that I've bought, but far from all:
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To be continued..
I have loads of pictures!
E24 635CSiA 85' (garage queen)
E24 628CSiA 83' (turbo/manual?)
E23 745i 82' (turbo project)
E23 728i 86' (745i project)
E23 728i 79' (part's car) [x]
E28 525i 81' (part's car) [x]
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M6smitten
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Location: Denver, CO

Post by M6smitten »

Great car, always loved the 745 turbo and ///M powered 745 SA. I could easily picture myself as a dictator in one of these.
2011 1 Series M
1974 2002 Turbo
1987 M6 (2/87) - Sold
1984 M635CSi (10/84) - Sold
2012 335 xi
2009 328 xi

Image
AusE24

Post by AusE24 »

Cool..Love it

Regards

Greg
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tschultz
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Post by tschultz »

Such a crazy car with a unique story!

Hilarious video: http://www.youtube.com/watch?v=MBIRNsGU8sI
http://www.Drive4Corners.com
Image
'79 635CSi Revival
'80 635CSi
'83 633CSi Callaway Turbo continued as 1988 535is Turbo
SOLD: '81 635CSi/A
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tschultz
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Post by tschultz »

Agreed, very neat cars!

My brother's. He love's this car and wants to restore it.
Image
http://www.Drive4Corners.com
Image
'79 635CSi Revival
'80 635CSi
'83 633CSi Callaway Turbo continued as 1988 535is Turbo
SOLD: '81 635CSi/A
///Moe
Posts: 284
Joined: Sun Jan 15, 2012 8:10 pm
Location: Norway
Contact:

Post by ///Moe »

M6smitten wrote:Great car, always loved the 745 turbo and ///M powered 745 SA. I could easily picture myself as a dictator in one of these.
AusE24 wrote:Cool..Love it

Regards

Greg
Thank you guys! :-)
tschultz wrote:Such a crazy car with a unique story!

Hilarious video: http://www.youtube.com/watch?v=MBIRNsGU8sI
I like that video too, it's a classic.
tschultz wrote:Agreed, very neat cars!

My brother's. He love's this car and wants to restore it.
-Picture-
He should do it if he wants to, these cars become rarer and rarer these days.
I think they will be harder to come by than E24, and the value will just rise.

Personally I prefer the preface version, which I have. :P
It looks more like an E24 in the front and have similar mirrors, but facelift ain't ugly.
E24 635CSiA 85' (garage queen)
E24 628CSiA 83' (turbo/manual?)
E23 745i 82' (turbo project)
E23 728i 86' (745i project)
E23 728i 79' (part's car) [x]
E28 525i 81' (part's car) [x]
///Moe
Posts: 284
Joined: Sun Jan 15, 2012 8:10 pm
Location: Norway
Contact:

Post by ///Moe »

Time for an update, then! 8)

Hung up on its stand, ready for disassembly:
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Not much left..
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Pistons all out.
If you take a close look you could actually see how bad some of the bearings was..
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The cylinder head I use come from another engine and was quite dirty to begin with:
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Valves before and after cleaning, what a difference!
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Installing valves back in with new seals, springs and retainers, after some cleaning and valve seat grinding:
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All back in place, it was a pain in the ass achieving that..
The upgraded valve springs are much stronger than the original ones and bent my tool several times along the way!
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New, steeper camshaft:
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Upgraded rockerarms vs original, they are a little bit thicker:
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Originals have a tendency to break, these wont..
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Shiny new rockerarm shafts:
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Rockerarm lock's completes it: :wink:
Image
E24 635CSiA 85' (garage queen)
E24 628CSiA 83' (turbo/manual?)
E23 745i 82' (turbo project)
E23 728i 86' (745i project)
E23 728i 79' (part's car) [x]
E28 525i 81' (part's car) [x]
///Moe
Posts: 284
Joined: Sun Jan 15, 2012 8:10 pm
Location: Norway
Contact:

Post by ///Moe »

Ok, let's continue where we let go..

Pistons, before and after I gave them a good handwash:
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Engine block decked and honed:
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New piston rings was a necessity.
One of the old ones were actually broken, but luckily still in place!
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Control measured them inside each cylinder bore:
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New, ehm.. Don't know what to call them in english:
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Reinforced, lighter H-beam rod vs original cast rod:
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Needless to say something.. :D
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ARP bolts
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New oilpipe and banjo bolts for the cylinder head:
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M106 oil spray nozzles, I retrofitted these into my M102 block:
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The id?a is that they'll cool and lubricate the pistons from underneath.
As you can see, also the engine block has been thoroughly washed inside..
Image

That's all for today, folks..
I hope it's not too many pictures at once!
E24 635CSiA 85' (garage queen)
E24 628CSiA 83' (turbo/manual?)
E23 745i 82' (turbo project)
E23 728i 86' (745i project)
E23 728i 79' (part's car) [x]
E28 525i 81' (part's car) [x]
///Moe
Posts: 284
Joined: Sun Jan 15, 2012 8:10 pm
Location: Norway
Contact:

Post by ///Moe »

ARP studs assembly:
Image

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Machined crankshaft + new sprocket because of wear:
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Crankshaft back in place with new bearings, not lubricated yet:
(I used oversize bearings for the rods, of course..)
Image

Had to clean these before assembly:
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I used ARP lubricant while torquing it down, and had some oil on every moving parts.
Image

New M102 3,2 Turbo headgasket:
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More ARP studs:
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Head back on! =D>
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New timing chain, oilpump chain, sprockets and rails.
I bought a new chain tensioner also, but have no pictures of it.
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How it should look when properly aligned:
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Before:
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After, with new seals etc:
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New and bigger turbo, better up to date and capable of more power!
Precision 6265 T4 / V-band, .81 a/r
Image

Waterpump.
Image

Stock E23 vs toothered from E34:
Image

Image

Starting to look good at this point:
Image
E24 635CSiA 85' (garage queen)
E24 628CSiA 83' (turbo/manual?)
E23 745i 82' (turbo project)
E23 728i 86' (745i project)
E23 728i 79' (part's car) [x]
E28 525i 81' (part's car) [x]
///Moe
Posts: 284
Joined: Sun Jan 15, 2012 8:10 pm
Location: Norway
Contact:

Post by ///Moe »

With a new and bigger turbo I had to build the exhaust system myself..
Aligned it all up to match the original turbo position and hit oem oil return hole in block:
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What I had to deal with:
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Welded it all together (in fact I did that after the engine was back in.. I'll come back to that..)
It was my first time doing something like this, plus I didn't have much welding experience from the past!
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My goal was to make it look somehow original, not badass.
Flow will never be optimal with this design, but it'll look anonymous.
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Finished result:
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Advantage with this design is that I can change spark plugs without having to remove anything.
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Mine vs original:
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It's incredibly compact!
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External 50mm adjustable wastegate, in the same area as the original one:
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Welded my own downpipe for it, shitty welds but you get the id?a..
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Welds could've been better but all in all I'm proud of this.
I'll make a heatshield above the exhaust when I'm done, turbo will be as good as hidden then.
I weighted it by curiosity and found my header with turbo and wastegate as much as 8kg lighter than the originals!

What do you think of my first ever exhaust header made? :-)
E24 635CSiA 85' (garage queen)
E24 628CSiA 83' (turbo/manual?)
E23 745i 82' (turbo project)
E23 728i 86' (745i project)
E23 728i 79' (part's car) [x]
E28 525i 81' (part's car) [x]
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JCS
Posts: 999
Joined: Wed Sep 22, 2010 11:06 pm
Location: Santa Ana, California, USA

745 turbo rebuild

Post by JCS »

Moe,

Very nice presentation, great photos, and text.
Also the before and after, very nice work.

This makes your work stand out, from any previous engine rebuilds i've seen.
Thank you for being very thorough.
Jay
'88 M6, Red/Tan
My NEW Website https://www.jaysbmwparts.com/
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DC
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Post by DC »

great work here ;-) i will steal some ideas from you :lol:

where did you buy these better rocker arms?
M6 - Marwin
628CSi Turbo - Britney
BMW-Faszination aus Technik und Design
///Moe
Posts: 284
Joined: Sun Jan 15, 2012 8:10 pm
Location: Norway
Contact:

Post by ///Moe »

I bought my rocker arms from www.pure-pf.com (PPF / Pure Performance Factory)
I still have a lot more pictures, but it'll probably be a bit too much if I use them all..
This thread is going to be a bit picture heavy on the first two pages, I guess.. :-k
E24 635CSiA 85' (garage queen)
E24 628CSiA 83' (turbo/manual?)
E23 745i 82' (turbo project)
E23 728i 86' (745i project)
E23 728i 79' (part's car) [x]
E28 525i 81' (part's car) [x]
///Moe
Posts: 284
Joined: Sun Jan 15, 2012 8:10 pm
Location: Norway
Contact:

Post by ///Moe »

Old exhaust system, which was noisy and hung too low underneath the car:
Image

New one, homemade:
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Mufflers that I used:
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Exhaust tips:
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Downpipe is 3,5" followed by 3" until the first muffler, then double 2,5" all the way back. Exhaust tips a little bit bigger than 2,5".
I find the sound ok now, it's louder than original, yet "quiet" and it has a nice deep sound to it without being to raspy.
You can hear that there is something extra underneath the hood, but it ain't screaming at you.. :-)
E24 635CSiA 85' (garage queen)
E24 628CSiA 83' (turbo/manual?)
E23 745i 82' (turbo project)
E23 728i 86' (745i project)
E23 728i 79' (part's car) [x]
E28 525i 81' (part's car) [x]
///Moe
Posts: 284
Joined: Sun Jan 15, 2012 8:10 pm
Location: Norway
Contact:

Post by ///Moe »

Finally a new page, it was about time.. :!:
I guess I'll have to torture you with more pictures now! :mrgreen:

New oilpump:
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Fitted with new bolts, shims and chain:
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Clean oilpan, ready to be assembled:
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Oil filter housing:
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Fitted to the engine:
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To maintain a certain standard I had to clean these parts as well:
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Years ago I painted them in BMW "Nogaro Silber", using professional automotive paint.
They could have been a little bit darker, but for now I'm pleased.
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I like the tube above the cylinderhead on these engines, it makes them look kind of special :P
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The lump on the tube is the original bypass valve, which is there to reduce lag and prevent rapid turbo deceleration.
Image
E24 635CSiA 85' (garage queen)
E24 628CSiA 83' (turbo/manual?)
E23 745i 82' (turbo project)
E23 728i 86' (745i project)
E23 728i 79' (part's car) [x]
E28 525i 81' (part's car) [x]
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JCS
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Location: Santa Ana, California, USA

Cleaning process

Post by JCS »

Moe,

Very nice.

What do you use to clean the parts, ie, valves, pistons, valve cover, oil pan.

I am interested in your secrets, please share.
Jay
'88 M6, Red/Tan
My NEW Website https://www.jaysbmwparts.com/
///Moe
Posts: 284
Joined: Sun Jan 15, 2012 8:10 pm
Location: Norway
Contact:

Post by ///Moe »

Then there was time for an engine swap! :P
After the 745i engine started to knock I had to put an M30B28 from my 728i part's car into it.
This was just a temporary solution so that I could use the car while overhauling the M102B32.
I ran it with the turbo setup for a couple of months until I bought my daily driver. (Mazda MX5)
The MX5 had to be welded and I ended up respraying the whole car, but that is a different story..

Prepared for the swap:
Image

On it's way out:
(M30B28 from 1979)
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Single mass flywheel, sachs 765 upgraded pressure plate and 6-puck sinterclutch:
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Pressure plate is dirty because I've been using it before.
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I bought this little worn out plastic thing for the clutch release fork, new:
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New transmission mount, along with new engine mounts (not pictured).
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Engine bay ready to recieve it's heart again:
(please ignore all the mess in the background..)
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Getrag 265 5-speed, prepared and ready:
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M102B32 Turbo, prepared and ready:
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Transmission bolted onto the engine again, it's been awhile since last time.
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Then it was time for the engine to go back into the car again!
The exhaust system was as previously mentioned not finished while this was being done.
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E24 635CSiA 85' (garage queen)
E24 628CSiA 83' (turbo/manual?)
E23 745i 82' (turbo project)
E23 728i 86' (745i project)
E23 728i 79' (part's car) [x]
E28 525i 81' (part's car) [x]
///Moe
Posts: 284
Joined: Sun Jan 15, 2012 8:10 pm
Location: Norway
Contact:

Re: Cleaning process

Post by ///Moe »

JCS wrote:Moe,

Very nice.

What do you use to clean the parts, ie, valves, pistons, valve cover, oil pan.

I am interested in your secrets, please share.
Thank you! :-)
I used various types of chemicals "not worth mentioning" to clean all the parts with.
My secret is that I used 3M Scotch-Brite pads to rub most of the dirt off. It won't scratch.
Automotive painters use them a lot before they respray cars, etc.
E24 635CSiA 85' (garage queen)
E24 628CSiA 83' (turbo/manual?)
E23 745i 82' (turbo project)
E23 728i 86' (745i project)
E23 728i 79' (part's car) [x]
E28 525i 81' (part's car) [x]
1988shark
Posts: 330
Joined: Fri Jun 15, 2012 2:08 pm
Location: columbus, OH
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Post by 1988shark »

[quote="///Moe"]Then there was time for an engine swap! :P
After the 745i engine started to knock I had to put an M30B28 from my 728i part's car into it.
This was just a temporary solution so that I could use the car while overhauling the M102B32.



Transmission bolted onto the engine again, it's been awhile since last time.
Image

My hats off to you. You got SKILLZ ! Making it look too easy, I want to venture off and buy some tools and do this shit myself. I have a 85Euro and parts from a 745 turbo to add on (turbo bits) will there be enough clearance in the 635 engine bay or will I need to make some modifications?
Now we need to see a video of you burning rubber in this baby!
///Moe
Posts: 284
Joined: Sun Jan 15, 2012 8:10 pm
Location: Norway
Contact:

Post by ///Moe »

I've seen 745i turbo parts on E24's and E28's before, I don't remember 100% what they did or not but they did some modifications.
I think you'll have to make space for the external wastegate as I believe it will hit the frame on your wheelhouse, but perhaps you could use another wastegate and / or mount it somewhere else. I'm not sure whether you'll have to do something to your engine mounts (I doubt..), but I've observed that Alpina B7 Turbo's have their turbo in front of the engine mount while on 745i's it's behind. Still there is space enough for a kkk-k27 behind it in E24's and E28's also, I think. Obviously you will have to make your own 'turbo to inlet' pipe and find somewhere for the intercooler to be mounted, perhaps a bigger one while you're at it. 8)

Unfortunately you will have to wait for the burned rubber a bit more, the engine ain't properly tuned yet. :(
What worse is: It's winter in Norway right now and I still have some work to do before I can say that I'm finished.
E24 635CSiA 85' (garage queen)
E24 628CSiA 83' (turbo/manual?)
E23 745i 82' (turbo project)
E23 728i 86' (745i project)
E23 728i 79' (part's car) [x]
E28 525i 81' (part's car) [x]
M635forever

Post by M635forever »

Kaempe gott arbeite du goer Moe!
Jeg har en M106 som ska ihop med en E9 3.0Csi.(gruppe 2 replica)
Og jeg veit vad f?r arbeide som ligger bakom att renoveire en motor som denne, och ?ven vilka penger det koster. Kudos!
///Moe
Posts: 284
Joined: Sun Jan 15, 2012 8:10 pm
Location: Norway
Contact:

Post by ///Moe »

M635forever wrote:Kaempe gott arbeite du goer Moe!
Jeg har en M106 som ska ihop med en E9 3.0Csi.(gruppe 2 replica)
Og jeg veit vad f?r arbeide som ligger bakom att renoveire en motor som denne, och ?ven vilka penger det koster. Kudos!
Takk! :P
Ja, det ligger mye penger bakom dette prosjektet.
Finnes det en tr?d / bilder av E9 prosjektet ditt?
E24 635CSiA 85' (garage queen)
E24 628CSiA 83' (turbo/manual?)
E23 745i 82' (turbo project)
E23 728i 86' (745i project)
E23 728i 79' (part's car) [x]
E28 525i 81' (part's car) [x]
M635forever

Post by M635forever »

///Moe wrote:
M635forever wrote:Kaempe gott arbeite du goer Moe!
Jeg har en M106 som ska ihop med en E9 3.0Csi.(gruppe 2 replica)
Og jeg veit vad f?r arbeide som ligger bakom att renoveire en motor som denne, och ?ven vilka penger det koster. Kudos!
Takk! :P
Ja, det ligger mye penger bakom dette prosjektet.
Finnes det en tr?d / bilder av E9 prosjektet ditt?
Kommer n?r projektet tagit lite mer form! ;)
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5280 M6
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Location: Denver, CO (5280' Elevation)

Post by 5280 M6 »

That engine is far too clean and pretty to get all dirty again by running it........I'd suggest you just encase it in plexiglass and exhibit it as automotive artwork =D>

Jim
'88 M6
'85 M535i
'84 911 Carrera
'12 Audi S5 (Daily)
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