91 318is Brilliantrot - A lot to refresh - Restomod - M52 swap

[Three3sheaven]

Subscribed. Our stories are VERY similar... I have a 318 brilliantrot that I am at the exact same spot in the swap, just got the M42 out and I just installed the M52 F1 clutch/lightweight flywheel. Although I'm going to take it apart to make sure I put the clutch in the right way for peace of mind - which apparently is very common to mistake.

I too have an e90 daily and am using the AKG mounts.

Anyways, what exhaust manifold are you going with? Are you keeping it obd2?

[AllydNYC]

Subscribed. Our stories are VERY similar... I have a 318 brilliantrot that I am at the exact same spot in the swap, just got the M42 out and I just installed the M52 F1 clutch/lightweight flywheel. Although I'm going to take it apart to make sure I put the clutch in the right way for peace of mind - which apparently is very common to mistake.

I too have an e90 daily and am using the AKG mounts.

Anyways, what exhaust manifold are you going with? Are you keeping it obd2?

:) That's a neat coincidence

I kept the OBD2 manifold. I'm sticking with OBD2. An exhaust shop will need to bend of of the header tubes to clear the subframe.

Starting to upload pictures for another update.

[AllydNYC]

To get up to current again, although it will take multiple posts:

Cleaning my M50 manifold with Simple Green, hot water and some brushes:


I also cleaned the ICV then got stuff mounted up. I ended up using the kit off of http://m50manifold.com/


If I see a gasket on the part diagrams on realoem, I try to replace it. Intake air temp sensor gasket replacment:


I had to purchase an M50 fuel rail with the FPR build in off of eBay. I didn't know this was necessary from all the swap threads I have read. A new Bosch FPR went in along with new Gates fuel lines and new hard lines:


I found a nice way of wiring up the backup light switch for my ZF320. I purchased a pigtail off of eBay for like $8 and soldered it up to the E30 reverse light wiring harness. It's a 'Standard S697 pigtail' and it worked perfectly.




I also got stuff to test fit the radiator in. This is something I do a lot. After years of figuring things out too late, I install stuff once or twice before the final installation to make sure everything is correct. This was no exception, one of the M42 plastic brackets that hold the radiator up was too small for a E36 radiator. I had to end up purchasing a new bracket for only one side to get the radiator seated correctly. I even purchased new rubber radiator feet and a bunch of other small parts for piece of mind and a clean job.

http://i.imgur.com/2zT2LaN.jpg

16" SPAL fan with gasket:

[FredK]

uh, is that the kitchen sink? ROFL

[AllydNYC]

It's engine time!

Here is the ZF320 bolted up to the M52:


With the help of a very good friend we got the engine in! It took a whole lot of angle to get this in:


Here it is finally seated after a good amount of time of playing around to get it to sit on the AKG engine mounts and be able to bolt up the transmission bracket:



I purchased, what I thought, was 2 transmission mount bolts and nuts from ECS tuning. Why not replaced them since they have been exposed to the elements for 25 years. The support chat told me they comes in back of 4 for $8. It ended up only being one bolt. Well, anyway I just went with one new bolt and one old one. Every new part counts!


New shift carrier bushing. $40 for this but I want the best shift possible and I'm down there anyway:


All new stuff. AKG aluminum cups with E21 mounts. UUC short shifter and DSSR. E36 M3 guibo, I know a bolt is missing. I was on one of my test installs.


The shifter sits off center but since then I got the rubber boot on and shifting doesn't feel off nor is it hard to shift into 5th:



I got my wiring harness from RobertK. It was an excellent idea to purchase it from him. I got some addition work done on it, SPAL fan relay integration, OBD2 port integration. I've never messed with any wiring on a car before. Hooking everything up was simple with the labels provided. This isn't the final result of me routing all the wires, just getting them ran.



SPAL fan install was very simple thanks to the harness and with a dremel and nice brackets.


I'm still not up to date. More soon, when I get some time.

[AllydNYC]

uh, is that the kitchen sink? ROFL

Hell yeah it is. I made sure to scrub it down with steel wool before I did this so I didn't end up with food in my engine.

[Poorhouse]

Awesome work!
In for more.

[c0rbin9]

You might want to try EagleOne Etching Mag wheel cleaner if you aren't completely satisfied with the simple green results. Often I find that parts don't get completely clean with just a degreaser and need something a little more powerful. The EagleOne is for wheels, but I had great results with it cleaning the cast parts of my M42. It's available at NAPA and a lot cheaper than sandblasting.

[iwantspeed]

Nice work on the engine swap

[AllydNYC]

Awesome work!
In for more.

Nice work on the engine swap

Thanks for the kind words!

[AllydNYC]

I purchased a remanufactured driveshaft from http://www.driveshaftspecialist.com/ . Not seen in the photo in all the new nuts and bolts to get it all in place and the new CSB. All OEM stuff.


I had second thoughts about my heater core. I remember that when the M42 was pulled that the previous owner plugged up one at least of the coolant lines with a bolt. I never had heat in the car so I decided to replace all the heater core stuff while I'm at a good point to do that. I purchased a new Mahle-Behr heater core, OEM O-rings, a new BMW heater valve and even the new aluminum hoses that connect it all up. I didn't want to have to do this again.

Unfortunately since at this stage I was close to being done with major stuff on the swap. I forgot to take picture as I became closer and closer to finishing.





Annnd the ̶c̶o̶o̶l̶a̶n̶t̶ fluid that was in the old heater core.


A 'while I'm in there' thing. Replaced the seal for the firewall that has the heater lines pass though it.

[AllydNYC]

I started the engine a few times and got most of the engine stuff sorted, so I decided to do something more relaxing. I have a video somewhere that I might post if I get around to it.

My girlfriend purchased me a new spoiler for Christmas last year and I haven't felt the need to put it on since the car was being worked on.



Here's the condition of the old spoiler/lip. I have to get that sticker off at some point. Scraping at it with my fingernail doesn't do anything:





Under it:


I cleaned up and waxed the area to protect the paint:


Boom!




Husco armrest time.

I didn't want to redo the top yet. I'll do that later on when I get my driver seat reupholstered.


Getting into the nooks yielded black water dripping out of it.



I got new hardware to install it. I put some caps on the screws to tidy things up.



Installed:
[IMG][/IMG]

I purchased a voltmeter nearly 2 years ago. I finally installed that. Along with that I installed my AUX fan override switch using an extra window lock switch.



Back to the engine bay.

I put a video together of my first (test) drive :-D . I had a GoPro mounted to my windshield but it stopped recording 20 seconds into the drive. I will be changing out the 4.10 diff for something else. It's just horrible, 3.2k RPMS at 50 in 5th and 1st 2nd and 3rd seem useless.



My first drive was a success! Here's what the engine bay looked like a few weeks ago before I took my first drive. I was about to add coolant, BMW coolant of course. The allen bolts are stripped on the AC line and I will eventually adding AC back to the car so, as for now, it stays ziptied to the windshield fluid container bracket. A lot of fresh stuff in here. NEW MAF, intake boot, vacuum hoses all new radiator hoses and even the hose clamps, coolant tank, brake booster, brake fluid reservoir, harness cover, seals, etc





And a picture in the driveway

[AllydNYC]

Last week I installed a fire extinguisher bracket and a class B,C fire extinguisher. The engine swap has me spooked that something will go up in flames and, of course, for the additional street cred.



I did about 45 minutes, 15 miles test driving in the community and decided the 4.10 has to go. Someone local is willing to swap me their 2.93 for this. I'll be picking it up this weekend, hopefully it goes through.

Good riddance.

[DealinDave@Blunttech.com]

Awesome to see everything come together. Great work on everything Ally

[jeenyus]

great progress! congrats on it driving. that arm rest looks pretty neat, and simple. I'd like to make one...