Post Your M/S5X 24V Swap Setup

[eandrade]

1. Engine
S52B32: full conversion over to OBDI (includes S50 valve cover, coils, fuel rail, manifold). I was lucky and the head had a 3rd pre-drilled hole for the coolant temp sensor.
Shrick street cams (intake/exhaust)
24lb injectors
3" stock MAF
Stock E36 M3 airbox

2. Engine Wiring
S50 harness. I didn't want to fuss with having to extend the ECU connector to reach into the glovebox (not sure how much of an issue this would have been with the E34 M50 harness)

3. Drivetrain
Getrag S6S-420G (six speed from E46 M3).
UUC lightweight flywheel (11lb steel)
E34 M5 pressure plate and sprung E46 M3 clutch disc
E36 325i clutch slave cylinder
S50 pilot bearing
Custom transmission mount fabricated by BNB Designs (user jrdreamicis on here)
Automatic E36 M3 driveshaft with E30 CSB (although I had to stretch it out more than I like where the two halves connect)
3.73 LSD (stock lockup) with finned MZ3 diff cover. The 3.46 is recommended here -- I'm not taking advantage of the torque in the lower gears with the 3.73.

4. Shift Lever and Linkage
Rogue Engineering SSK
E46 6spd shift knob
No need for any custom bending here since the 6-speed isn't clocked

5. Motor Mounts
AKG Poly with custom spacers from BNB Designs

6. Brake Booster, Master Cylinder, and External Reservoir
E32 booster
E32 master cylinder with remote 2002 reservoir (which has 3 outputs so I didn't need an extra reservoir for the clutch fluid)
Shaved the last 3 intake manifold fins off for a little extra clearance.
The Massive race kit that I'm running is so much brake awesomeness that I think I could live without a booster…I might go this route to clean up the bay a little more.

7. Steering System
Z3 steering rack into stock steering knuckle (I have a '90 airbag car). Used about 3 spacers (S5x head bolt washers) on each of the mounting bolts. Custom lines to/from rack, pump, and stock E36 M3 reservoir (mounted on engine mount arm).

8. Cooling System
M42 radiator to eliminate need for external expansion tank (after BNB designs relocated my ABS to the passenger side battery tray, this gave me enough room to run a stock E36 airbox). Pusher fan in front. No fan on engine side. Lower temp thermostat and AUX cooling fan switch (which is feeding the pusher). I think I'm going to have to go with a larger customer sized radiator here since it runs a little hot on track.

9. Exhaust System
Stock OBDII exhaust manifolds (with O2 sensor bungs plugged by Toyota Tacoma oil pan drain bolts) into custom x-pipe containing O2 sensor into stock OBDII mid-pipe (secondary O2 sensor bungs also plugged). Then custom pipes and hangers to Eisenmann Race exhaust.

[ian e30 318is]

Awesome posts Frankie and Janderson.

great information! thanks man :)

No problem sir :D

What all do you need to BAR it? Do you have any tips on passing the BAR 'test'?

It actually was pretty straight forward where I went (referee station in Miramar/San Diego Area). The main things they told me they look for is that:

1. Everything regarding the engine needs to be from the existing car that the engine came out of. So an e36 engine needs to have e36 components which includes everything back to the catalytic converters. I used two stock e36 cats with my setup. The exhaust after the cats can be anything you want.

2. No check engine light can be present when the engine is running, but it must also function (i.e. when the car is in auxiliary mode).

and most importantly
3. The engine must pass the SMOG test which is conducted at the BAR station (at least at Miramar).

I passed with a K&N cone filter so I think they were pretty laid back, but as long as everything looks good and works fine you should pass with flying colors. I was pretty nervous when I first got there, but the guys that worked there ended up being pretty nice. Hope that helps.

Keep this thread going. This is very informative!

I agree!!

[Jand3rson]

1. Engine
Non-VANOS M50B25 from '92 525i.
Replaced all seals and gaskets prior to install, SKF Speedi-Sleeve on crankshaft rear main seal.
Kamotors intake w/ E34 intake boot.

2. Engine Wiring
E34 525i harness, hard-wired directly into X20 connector.

3. Drivetrain
Fully resealed Getrag 260, New Sachs OEM clutch and pressure plate, E30 pilot bearing.
Stock E30 driveshaft to fully resealed S3.73 LSD. White325is transmission mount w/ stock rubber mounts.

4. Shift Lever and Linkage
Z3 1.9 shift lever, AKG Delrin shift carrier bushing, solid bolt mounted to new OEM aluminum shift carrier.
UUC DSSR w/ all new washers/bushings, Delrin shift knob.

5. Motor Mounts
E28 535i green mounts.

6. Brake Booster, Master Cylinder, and External Reservoir
Porsche 944 Girling booster, resealed OEM E30 master, new OEM E30 fluid reservoir.

7. Steering System
E36 328i steering rack, OEM E36 supply and return hardlines, new OEM fluid reservoir, cut/modified E30 softlines.
Cut/shortened E30 linkage, guibo removed.

8. Cooling System
OEM M42 radiator w/ 16" SPAL pusher (no stock engine fan), metal impeller water pump and Z3 1.9 radiator/fan temp switch.
Stock E34 hoses cut/modified to fit, stainless T-Bolt hose clamps.

9. Exhaust System
Ebay Supersprint rep headers, ceramic coated inside/outside, Flowmaster dual 2"-into-2.5" Y pipe.
V-Band clamp into 2.5" Borla ProXS center muffler, no cats, single 2.5" piping to second V-Band clamp, single 2.5" piping into 2.5" Vibrant StreetPower rear muffler.

[jaywood]

Keep this thread going. This is very informative!

[frankie591]

1. Engine
M52b28, full OBD-1 swapped, s52 cams, ported and polished head, tuning from TRM. Replaced most seals and gaskets prior to dropping in the engine.

2. Engine Wiring

e34 525i harness, spliced on an e30 engine side c101 to connect up to the chassis side wiring.

3. Drivetrain

Getrag 260, new OEM clutch and pressure plate, e30 pilot bearing. Used stock driveshaft and 3.46 lsd. Revs are right around 3k at 120km/h on the highway. Custom modified my stock trans brace to mount the trans on an angle, and used the more solid e21 trans mounts.

4. Shift Lever and Linkage

b&m short shifter and all new bushings. Replaced the bitch clip with a bolted connection to make it easier to remove if I need to.

5. Motor Mounts

e28 535i mounts, no spacers above or below the mounts.

6. Brake Booster, Master Cylinder, and External Reservoir

Stock booster slotted over half inch. Cut and welded the clevis so the linkage is still straight. Shaved the last 3 intake manifold fins off for a little extra clearance.

7. Steering System

m52 return line, and e30 supply line. e36 reservoir mount. Did an e36 rack as well, cutting the rubber flex disc out and solid mounting the 2 sides of the linkage together in order to shorten the linkage by ~.5". Steering is nice and lively now without the dead zone that used to be there because of the guibo.

8. Cooling System

e36 radiator, late model e30 expansion tank (I have an early model car), 16" summit racing pusher fan wired into stock aux fan wiring. Low temp thermostat, and lower temp aux fan switch. Got some generic rad hoses from NAPA and cut them to fit the hot and cold side.

9. Exhaust System

Raceland longtube headers. Had to dent in the subframe, bend the front swaybar and dent the header to make them fit. I wouldn't suggest these headers as it was a royal pain in the ass to get them to fit. Did my own custom 2.5" system with 2 straight through mufflers and a hi-flow cat. Sound is nice and quiet at idle, not too much rasp, and screams at high rpm.

-Andrew

[Vivek]

What all do you need to BAR it? Do you have any tips on passing the BAR 'test'?

[E30FreaK89]

great information! thanks man :)

[ian e30 318is]

I know the "Comprehensive DOHC" thread is out there, but it is getting very cluttered. I figured posting up complete and running 24v setups might help people with questions they may have on which parts to use on their own swap. Feel free to post your setup and to ask questions.

The following is the way I did the swap in my 318is, but there are MANY options. Hopefully others will post what has worked for them.

1. Engine
I ended up buying a S50B30 OBD-I engine from a guy down in San Diego. I also purchased an e34 525i oil pan, pickup tube, dipstick, and throttle cable (this item I purchased new). While the engine is out of the car I recommend replacing the routine items such as head gasket, water pump, spark plugs, oil pump nut (I used red loctite and a drilled nut), tensioning pulleys, and possibly the VANOS o-rings and spacer. For the VANOS rebuild, I utilized the single vanos rebuild kit from http://www.beisansystems.com/. I also had the head rebuilt at Hopsing Machining in San Diego. He does great work for the price.

2. Engine Wiring
The wiring harness I ended up using was from a e34 525i that I picked up from Autobahn in San Diego. There are many wiring harness adapters that can be used, but I opted to repin the harness into the existing connector using a special BMW repinning tool and new pins. I have a few color diagrams available for those interested. If anyone needs one please feel free to PM me.

3. Drivetrain
I bought a Getrag 260 with a stock 325i driveshaft and a 3.73 LSD. I could have reused the Getrag 240, but opted for the larger transmission because of future plans with the engine. This setup required a swap brace that is rotated 10 degrees which can be attained from white325is on here. I used the e21 320i solid transmission mounts and the Z3M differential mount with the setup as well.

4. Shift Lever and Linkage
To go along with the drivetrain, I purchased a z4 2.5 shift lever and the AKG dual sheer selector rod. Since the transmission was rotated 10 degrees, the DSSR was cut in half and rewelded at a 10 degree angle to match the rotation. I have seen now that UUC is possibly making a "bent" DSSR which would be a great option for people wanting to stick with the Getrag 260. I highly recommend the DSSR. There is absolutely no slop in my shift linkage anymore. I also recommend refreshing the bushings and washers in the shift linkage at this point in time while everything is out of the car.

5. Motor Mounts
I utilized the AKG motor mounts that are solid urethane. Although this is a bullet proof setup, it does rattle the hell out of my car at idle. I would recommend the e28 535i mounts for a smoother ride, but make sure you get the OEM ones for the extra cash. I have heard a few stories of some other mounts shearing in half and damaging radiators and pulleys. Here is an installation guide for the OEM ones: http://www.akgmotorsport.com/e30convinstr2.html

6. Brake Booster, Master Cylinder, and External Reservoir
The brake components I utilized were the e32 735i booster and master cylinder along with the 2002 remote reservoir. No modifications were necessary for the booster and master cylinder. The 2002 reservoir required a remote mounting location and a supply and return line both leading to 2002 plastic elbows shown in the diagram as #12 and #14 http://www.realoem.com/bmw/showparts...08&hg=34&fg=25

7. Steering System
I ended up using the e30 steering lines but heating and bending was required to make them fit. This was not easy and took some time. Just be patient and persistant with this step.

8. Cooling System
I opted to use a e36 radiator with a 16" Spal puller fan for the cooling system. I reused the e30 325i external coolant reservoir and purchased silicon hoses from Rogue Engineering. Before I installed the puller fan, the engine would slightly overheat with a fan delete kit (http://store.bimmerworld.com/e36z3-6...-kit-p582.aspx), so a puller/pusher fan is absolutely necessary. Also do not purchase the water pump shaft nut. Mine didn't fit.

9. Exhaust System
I ended up buying an e36 Rogue Engineering cat-back exhaust from Levent. The stock exhaust manifolds were ceramic coated black and a custom midpipe was put together by RPM in Oceanside with the stock e36 cats (for California BAR purposes). The cat-back doesn't fit well and some custom work on the battery tray needs to be done to tuck the exhaust up a little more, but overall I am happy about the look and sound of the exhaust.

I am extremely happy with my swap! Hopefully this thread helps with some questions people may have. I can also add pictures if requested. Thanks for looking.

-Ian