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Discussion Starter #1
Hi all been away a while but have had this project the past year which i've taken on a little over a year ago


It was half finished when i took over from it








Take one smashed up Bi turbo no. 389







And refit it all into this Touring. This car was sold new in Holland as a special order Avus blue 525i manual touring. It also came well specced with heated sports black leather trim, air con, double sunroof and cruise control. So a very nice 525i touring!




All this was done by the previous owned who bought the bi turbo and touring and sent it to a garage to complete the conversion. Wind forwards about 8 years and this is where i came in when it was offered to me. I'd known about this car since the start but never thought i'd have a chance to own it!




I guess a little background, i've had a bi turbo before as some might remember on here





No.445 fully loaded one, had it about 2 years. Rear turbo blew, clutch went, snapped 2 rockers, and alot more went wrong! Its serving its new owner very well by all accounts. These are a missle when they work, nothing on the new generation of turbo M5s but still impressive in the right situation. Sold it and bought this below





6 speed M5, so was offered said project and this had to go, i should of kept it really. Best E34 i've had was a great car, the only thing better than an M5 saloon is a touring! I'd always wanted one but this came along and its like the ulitmate E34 touring that was never made from the factory a Bi turbo touring! onwards with this thing














Sat here literally for years at CPC, still i agreed to take it on. Heres what i found intially, boxes of bits stored upstairs also and scattered all over the workshop







loaded up on a trailer and literally a van load of all the other ****




General theme on this is, electrics incomplete, lots of parts missing. So its been Mr. Detective and observant, if only it was an E30 as i'm sad enough to remember the whole car nearly, not quite like that on e34s

Plan has been to sort all the electrics and get the car running, then strip it all back down. Sort what needs doing and put it back together and use it. Going to be a long road as its the worst thing, taking on and finishing someone elses half finished project. It would of been lovely to have got the old written off Bi turbo aswell plus this car and done it. That would of been easy!!








First job was to fit a battery and see what worked and what doesn't. Lights hmmm, tailgate wiper and washer sprag to life! Even the struts hold the glass up - thats rare on e34 tourings these days and changing the shocks is tricky


Not much else worked really, engine bay as dead as a dodo









Engine earth strap was missing, a tempory one to get the ball rolling and the battery positive from the jump point to starter motor, fairly major!








That sprang alot more into life, so windows and heated seats and lots of other bits.






clocks, missing all the bulbs and the back. Plastic screen broken in the accident. Not many bi turbo clocks going spare so will have to make do with this!





picked this up and fitted as many bulbs as were missing






Most of the wiring for the lights on the front needs repair on the connections as only 1 main beam lit up the rest nothing!

No indicators but traced that to a missing relay



Lots more bits to come i'll up date later on
 

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Discussion Starter #4
Some more wiring snaps,






Wiring for the alpina guage i'm pretty sure as i did it a while back. Had to run this through the bulkhead/fuse box






A quick test on the alpina guage shows it powers up with the ignition on, its reading too. So thats a good sign. Just needs the illumination wiring in and it will power the screens up





these pins needing wiring into the cars body loom, matching the colours up the other side of the plug. I forget what this loom is now but its bi turbo wiring not standard BMW






Body control module was missing










module fitted and then i removed the old Alarm and its wiring









Wired the old pioneer amp back in and hey presto the radio worked! Theres a whole old skool pioneer sound system in there, speakers and a big old CD changer in the boot! which doesn't work








Wiring mess, these white plugs do not match each other, one being bi turbo or M30 and the other being M50. BMW must of changed the plug for some reason along the line. So i need to source a matching plug. But first i need to identify what the wires do each side of the plug and see which ones match. Seems to me maybe its OBC as that doesn't work at all






I found this potentiometer in an oily box! A rather expensive part. throttle now opens with the ignition on. I just need to work out now how it mounts and remove the old throttle cable set up for this fly by wire. I'd seen the big black plug hanging for some time and wondered what it was for. It all came to me in the shower that these would match together!






Next up these dealer wiring diagrams from a good friend at BMW, then i needed a friend to read them properly.






Engine is dead and won't crank anything.......so testing with the voltmetre and several checks led us to................the front fuse/relay box






This is the starter motor relay, now if you have an automatic car one of these is fitted from factory. Now studying the wiring diagrams reveals that manual cars dont....


We had already established that the ECU was getting 12V's and the ignition switch was working. But something was stopping the starter from getting 12 volts. This relay






cheeky bit of wiring bodging to bridge the wires.................and hey presto the engine CRANKS! this has been mega exciting!

We have spark, which means crank sensor and rest of ECU is fucntioning. No fuel it seems, pump maybe injectors as its not run for 10 years. I did crank her over to get the oil pressure up and see if she'll fire but to no avail. So thats my current point with it really








This is the boost ECU and this little black hose runs to the inlet manifold, the way it attatches to the ECU is with this special little screw in bolt - yes this was missing so i had to get my dad to machine up a new part so it all connects correctly again








I did look at the fuel pump, hardly any fuel in the tank. Anyhow it seems dead and different from standard but not in alpina way? The hoses are all perished anyhow. A picture next to a standard fuel pump









On the subject of fuel, i managed to buy a decent metal M5 fuel tank so 90 litres instead of the standard 80 litre plastic tank in due course. Every little helps as these cars aren't good on fuel! The extra 20 litre alpina tank is missing, i'm not sure it could be made to fit in a touring anyhow









Next the intercooler, this was damaged in the accident so has been repaired. Also the 4 brackets that mount it were damaged also. These were bought from Alpina!









Stripped the front end down and mounted the intercooler in place







The front bumper needs cutting as the intercooler is in the way from it mounting properly












Some cutting in the places shown and...............






front bumper fits! Now i need to order a new Bi turbo front spoiler from the dealers, ouch. It was damaged in the accident.

Unless anyone has a spare one to sell me?!?! thought not. Its quite alot of money new! Alpina list a bumper and other parts but i'd be guessing its how i 've done it.









So thats it up to date really and as she sits, a bit more in the right direction to being a car than a lump of parts. I've got lots of other good bits to fit to this also. I'll get some pictures of them in due course

I'm hopefully moving house* so will need some time to move get set up. But a much nicer place to keep this and work on it
 

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Thoroughly admire what you're trying to do - good luck. Let me know if I can help with photos from my BT on anything you're stuck with.

Cheers,

Dave.
 

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Discussion Starter #7


despite moving house i've still managed to collect some much needed alpina morsels. The all important front spoiler new, i got a very good deal on it! Theres more but i'm still in chaos here and car tinkering time is still a way off sadly
 

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Discussion Starter #8
So a little, update a vain one but who cares as it helps with the inspiration!




I got this before christmas, my old saloon had the same wheel. Its nice and better than all the ****e airbag efforts offered by BMW at the time. (Safety aside!)





I've got a bit less room here so i thought i'll fit the wheels then, i'm not storing another set!







took a long time as every rim was corroded onto the hubs so some violence was needed to remove the old metric rollers, much better?




So onto fitting the front spoiler, this took a long time to get it right, as i didn't have a stencil and there were holes that needed drilling! bit of picture dump here




interesting sticker for a geek, is that the date time said bumper was manufactured i assume



















The amount of cutting as seen in older posts is alot on a poor standard bumper. You could always go to Alpina cap in hand and buy all the specific parts they made for this, I simply don't have that budget and this fits well now








The money shot







I've got a pre facelift grill also. I think this looks better and you have room to fit a front bi turbo badge. Its more work though and i don't think the wide grill looks to bad now i've seen it in the flesh rather than pictures












Time for a well earned wash i thought yesterday













A bit better, I'll keep going with stuff until my more clever friends arrive and we can sort out why engine is not getting fuel soon. because with fuel it should start!
 

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Nothing wrong with a moral booster to keep the project alive - love the colour and I think a BT Touring should have been a factory choice from the beginning.

Keep going, very keen to see you fix those loom issues and the temp gauge is having a party all by itself it would seem :D

Do all your pumps work on the bench by the way? I changed my Alpina pump once as it dropped pressure and the car ran like a dog - these pumps are uprated for the BT and very expensive from Alpina. I decided to go original but others have used Walbro pumps with some success I think.

Once it starts, what else do you have to do?

Dave.
 

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Discussion Starter #10
Hi Dave any more info on the fuel pumps? I wasnt' aware they were different so thanks. I'm yet to test the one that came from the car yet, i need to.

My plan was to get it running at first, then properly. Maybe get the car going moving to a state of MOT. But the whole car needs going through really. Suspension, brakes. Once its running driving as it should i'll probably strip it down. Get the turbos off and checked/rebuilt plus some other pro active stuff.
 

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Discussion Starter #14

The eagle has landed, my mate runs a BMW specialist BMR. So I've had it recovered here and the guys are going to get this sorted and the engine running. just had to be patient and wait until they had cleared a few big projects out the way. Its cranking over with spark, but not getting fuel for some reason, pump is working
My old Bi turbo is here so a handy reference for them!
 

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Excellent - after all your hard work, I hope the problem was tricky enough to justify paying hard earned cash for someone else to claim the glory? What was it in other words?

The Touring is the perfect base for the Bi-Turbo. A couple of years ago I bought a new 340i M-Sport Touring as I love BMW's in the touring body and you lose nothing of the comfort or fun factor. The BT is up on power of course and the torque shove is on another level - I'm going to follow the rest of your build with interest.

Cheers, Dave.
 

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Discussion Starter #17





Popped up to BMR to deliver some parts from the stash to help it along. The plan is to make it turn key start as such with the cooling system bled up. They're sorting the throttle pedal, some wiring and getting the brakes/clutch bled up hopefully without too much drama and I can get it back home as a moving live car and work from there rather than still a dead driveway ornament. I can't afford to leave it there for the full monty. Nice to see it there with my old car, no.445. Looking epic it is. Brought my daughter home from hospital in it after she was born. Also for a much healthier bank balance I should never of sold it!!

Dave I was in a mental rut with it and needed some fresh eyes on it. Yes all simple things to sort snag out to fire her up but Barry is a long time friend long befre he set up his BMR bmw specialist and Mark who works for him is mustard. Hes an old boy who loves a challenge and was in the BMW network when e34s where still new! Its hard earned well spent i'd say, as car is worth more, re lit my fire to see it into a car now
 

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Funny how the stars align - I've been talking to Barry on and off for a year now and have promised myself to pay his workshop a visit once my BT is back from it's bodywork restoration project. That said, for anything mechanical I don't do myself, I've used Phil Crouch who has delivered excellent service and knows the BT very well indeed - a total genius on electronics (EML repairs etc).

I also used my BT to bring my son home from hospital as well - glad I wasn't the only one! He was also in it some years later when he went above 100mph for the first time (Dad's remember all the important stats...)

Glad to see you're moving forwards, once it's turnkey and moving under it's own power the rest will be easy :)

Cheers, Dave.
 

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Discussion Starter #19
Well time for an update, its been a while but theres been plenty to report and 95% of it all good.


I went back around chirstmas time to BMR to drop off some more parts required. Some rear shocks and springs and other parts my memory escapes me - front spoiler!

found this alpina part in a box, it allows the towing eye to fit with the front spoiler fitted - quite handy then!!


She came home last week. I'm a bit short on pictures but i'll try and remember all the stuff BMR have done.



It actually moved itself to here on the drive under its own steam! Then I gave up as it kept cutting out and the gearbox isn't great but i'll come to all that in a minute



4 hours and BMR had her running
DME wiring needed a repair to a wire that was shorting out! So potential fried ECU but the Gods have been kind here, must of been a chaffed wire from the engine swap is a guess
Crank sensor was dead so no spark - new one fitted
fuel pump pipes were fitted wrong way round, which in turn when cranking over took out the fuel pressure regulator. As fuel was being forced upon it from the pump. M30s use the same normal 3.0 bar one as fitted to E30 325i's of which I have a few spare
Engine sounds healthy and backs up i'd say with the Bi turbos historys and suggested milege of around 130,000KMS or 80k miles before the crash. Top end sounds good but will check tappets in time


Cooling system has been bled and no big dramas here, this AUX pump was missing so a new old stock item found on german Ebay. Its used to cool the turbos after the engine is switched off. Not sure its job on normal BMW e34 e32s as its a normal part but is listed with a option maybe?
Also a new water pump and thermostat has been fitted, no over heating from engine and the heater is blowing hot


New PAS pump. The SLS system had some expensive and NLA parts from BMW parts missing. namely the levelling valve and pipework to it. Surprise!



Ebay again found me this non SLS PAS pump for M30 engined cars. Then it wouldn't fit as non SLS pump brackets needed to mount it to engine were NLA from BMW. Bmw breaker Tim pollock to the rescue here! Then after the pump was mounted it was found the pulley was different for non SLS to SLS! So Tim again to rescue with the correct pulley
So power steering sorted and now i'll need to use a normal shock spring set up on the rear. I'm planning on using bilsteins with some H&R M5 touring springs


Brakes wise, the system is bled up ok but one of the rear calipers is seized or rubber the line has collapsed but it stops on 3 which is fine for driveway work and the Alpina 4 pot brakes need fitting yet also which I luckily have. Its currently on the 525i brakes which are rather sad after all the years sitting


picture is from my old bi turbo,
clutch - again a few dramas it wouldn't engage when the pedal was pressed from what I can work out the clutch fork was seized on from all the years sitting. It was freed off and the pedal worked.
The clutch is supposed to be new from talking to Charlie the previous owner as he bought one, but until I take the box off I won't know for sure. The pedal doesn't feel it to me. Fingers crossed its there as a new clutch 6 years ago was over £1000


I've nicked this picture from my old car, Gearbox - had no oil in it same as diff.
At first after oil was added it wouldn't engage any gears at all. Great. Then with some work 3rd, 4th and 5th engaged with the car running on the ramp and some trade tricks
Then 2nd and 1st. but no reverse. That has since returned. although its hard to tell if you are in 1st or reverse and its quaite reluctant to engage 1st 2nd and reverse so I think i'm going to have to pull it out and get the box checked. Its like the detent springs are seized or something. I'm sure its age related to the fact its sat for years with no oil in it. The boxes are up to the job on these. It maybe of a case that the box needs some heat and driving to get it back into life

So that was the great work done by BMR a lot of work and knowledge to get us here and re light the fire to see it through after 2 years!
 

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With the car home the direction i'm taking is to get the car ready for an MOT, which will be no mean feat but very much possible now


Last weekend I set to it and put the interior back into shape as its a bit of state



I've swapped the clocks to the normal ones as the alpina ones are ****ed and the temp guage has took a ****, can be sorted later. Milege is incorrect. The cars done 270,000kms but the engine 80k miles? what do you do there then!

Heres how this area looks on a normal bi turbo, with the boost dial and ASC traction switch




This was my idea for the touring, namely as the touring doesn't have ASC traction control fitted so whats the point in the switch? Its a quite scary/fun thought of this car with no traction control as they light the rear wheels up with ease in rain or shine with 400lbs of torque. Alpina gear nob needs a repair and is with my Dad.


alpina sill trims fitted. Drivers one is damaged, alpina will sell new but they are expensive




Its not looked like this for a while! Glove box hinges are missing so sourcing some now and theres a bit more wiring to do yet with the alpina extra guages before knee rolls can go in drivers side.


A friend was clearing out his parts and found this bi turbo undertray which was missing so a lucky find!


I've removed the spark plugs, nice to see 3 different types fitted. Also injectors off for refurb, along with the MAF but i'll update that next week or so as i'm going through the engine and sensors in an effort to get it running spot on. So I can park it properly and get my E30 out as its blocking it in at the minute


Here she sits and the buzz is back. Keeping the money flowing for it and dedicating time are the main challenges now but my aim is to have it MOT'd this year as the momentum is there now. The list is very long and lots of quirky expensive bits to buy and find but the end result will be worth it. I've also sourced some nice retro fits and upgrades which I'll get to later over winter. Nothing Max power fear not
 
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