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    #46
    Originally posted by wildstoats View Post
    Whoa! What the hell caused that?
    When I removed the hoses there was a lot of what seem like calcium deposits. I removed all the white buildup with a wire wheel but under that there was that hole. I ended up getting a new cover.

    This particle from Pelican might explain what happened.

    Electrolysis

    One failure mode associated with dirty coolant is known as electrolysis. Electrolysis occurs when stray electrical current routes itself through the engine coolant. The electricity is attempting to find the shortest path, and impurities in the coolant often generate a path of least resistance that the electricity travels across. The source of this stray electricity is often from electrical engine accessories which have not been properly grounded. A missing engine or transmission ground strap can also cause the coolant to become electrified. Sometimes the path of least resistance becomes a radiator, a heater hose, or even the heater core. These components are often well grounded, and offer a ground path from the engine to the chassis by means of the semi-conductive path of the coolant.

    Electrolysis can destroy your engine quickly. Although it's semi-normal to have very small amounts of voltage potential in your coolant system, values greater than about a tenth of a volt can start reactions between the coolant and the metal in your engine. In particular, electrolysis affects primarily aluminum engine components, resulting in pitting and scaring of the aluminum surface. This eating away of the metal can cause coolant system leaks, and in particular, radiator leaks around aluminum welds. Cast-iron components are also vulnerable, but typically the aluminum metal parts fail first. On BMWs in particular, electrolysis can be easily seen attacking aluminum cylinder heads. Figure 1 shows a picture of the thermostat area of a cylinder head that has been partially damaged by electrolysis. Notice how the aluminum has been eaten away, and eroded by the chemical/electrical reactions.
    The process works somewhat like electrical discharge machines (EDM). These machines work by passing a large electrical current through metal, literally zapping away bits of material until nothing remains. Unfortunately, the electrolysis process works in a similar way, zapping bits of metal in proportion to the amount of electrical current passing through the coolant. A poorly grounded starter can literally destroy a radiator or head within a matter of weeks, depending upon how often the car is started. A smaller current drain, like an electric cooling fan, may slowing erode components over many months.

    How can you test for electrolysis? Other than actually seeing visible signs of erosion, you can perform a current flow test. Connect the negative terminal of a voltmeter to the chassis ground. Test for adequate continuity by touching another point on the chassis - the resistance should be near to zero. With the engine cold and running, submerge the positive probe into the coolant tank, making sure that the probe does not touch any metal parts. The voltage should be less than .10 volts. If not, methodically turn off or unplug each electrical accessory until the reading reads below .10 volts. Have an assistant switch accessories (like the A/C compressor, heater blower, etc.) while you measure the voltage.

    If an accessory doesn't have an on/off switch, test it by temporarily running a ground from the housing of the accessory to the chassis. Ground each component and check the volt meter. If the wire restores a missing ground connection to the accessory, then you've found a component with a faulty ground.

    During this test, be sure to check the starter. Not only will a poorly grounded starter struggle to turn over the engine, it will also zap away tremendous amounts of metal in your cooling system. Watch the meter carefully when starting the engine. Any voltage spike will indicate a faulty ground connection.

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      #47
      M30 swap finally moving forward

      Finally I was able to get back on track with the project. I was able to find a rental company that had an impact wrench gun rated to 475 ft pounds so I was able to get the "Jesus" nut off. Even then it took several tries to get it off.
      Click image for larger version

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      I made a tool to hold the crankshaft from turning. Cheap but it works.
      Click image for larger version

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      I'll be replacing the plastic bits tomorrow.
      Click image for larger version

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        #48
        looking good so far keep us posted man

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          #49
          Looking real good.

          I like the tool you made to keep the engine from rotating. I used a small block of wood and stuck it between the head and the block but your way is probably better...
          '86 E30
          '05 E53 X5
          '72 Firebird
          '10 Prius
          '03 Tundra

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            #50
            Originally posted by JoeMadoo View Post
            Looking real good.

            I like the tool you made to keep the engine from rotating. I used a small block of wood and stuck it between the head and the block but your way is probably better...
            Yeah I thought of using a 2x4 but with my "tool" I have the engine locked at TDC.

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              #51
              M30 chain tensioner question

              So for those who did the swap. How did you bleed the tensioner and did you have problems keeping oil in the reservoir in the cover?

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                #52
                3/12/2010 update

                So I bled the tensioner the way the Bentley indicated but I turned the engine over to install the oil pan so who knows if it is still good.
                Here are in all their glory the new plastic rails, guides and tensioners (timing chain and oil pump chain)

                Click image for larger version

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                I broke the bolt that holds the camshaft adapter. There is a $.49 copper washer between the bolt and the camshaft that you are suppossed to replace everytime you torque the bolt so I spent half a day driving around looking for it.

                Click image for larger version

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                I plan to take out the old engine next week and hopefully install the M30 the week after.

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                  #53
                  M30 swap update

                  So I rented a torque wrench to install the crankshaft nut. That thing was so huge it looked like something out of a cartoon.
                  Click image for larger version

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                  While installing the wiring on the alternator I discovered one of the connectors was broken. A little solder, shrink tube and the soldering iron took care of that.
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                  More tomorrow

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                    #54
                    Awsome progression on this project dude! It looks great so far.
                    Curious, why are you wearing sunnys in the first picture of post #53? Maybe you should have just turned the lights out i it was too bright? lol.

                    Keep the pics coming!
                    ///Monstrosity. (OO≡≡[][]≡≡OO)

                    Aside from showing yourself to be offensive, lacking experience and ignorant in the ways of business, you're also illiterate and imprudent. Beyond that, your sense of liability is severely impaired.

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                      #55
                      eye protection?

                      looking good!

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                        #56
                        Originally posted by Doughnut View Post
                        Awsome progression on this project dude! It looks great so far.
                        Curious, why are you wearing sunnys in the first picture of post #53? Maybe you should have just turned the lights out i it was too bright? lol.

                        Keep the pics coming!
                        They are actually Bolle's with lenses that turn dark with sunlight and clear inside plus they have a prescription. I use them as my safety glasses.

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                          #57
                          Transmission and shifter question

                          So looking through all the swap write ups there is no mention of transmission seals being replaced. Are they necessary?

                          Any recommendations for a short shifter? I'm replacing all the bushings with OEM parts unless there is something better.

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                            #58
                            - from what i've read and been told you don't want to touch the tranny selector rod and output shaft bushing unless you know exactly how to do it right otherwise they will leak. The input shaft one you can swap if it's leaking.

                            - shifter, yes z3 1.9 is a good one to use. and get the AKG shift arm bushing, the stock rubber oem bushing is flimsy even brand new. I've done 2 complete shifter rebuilds on the old style and new style shifter consoles.
                            Mtech1 v8 build thread - https://www.r3vlimited.com/board/sho...d.php?t=413205



                            OEM v8 manual chip or dme - https://www.r3vlimited.com/board/sho....php?p=4938827

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                              #59
                              Originally posted by Jean View Post
                              - from what i've read and been told you don't want to touch the tranny selector rod and output shaft bushing unless you know exactly how to do it right otherwise they will leak. The input shaft one you can swap if it's leaking.

                              - shifter, yes z3 1.9 is a good one to use. and get the AKG shift arm bushing, the stock rubber oem bushing is flimsy even brand new. I've done 2 complete shifter rebuilds on the old style and new style shifter consoles.
                              Thanks Jean. I knew you had the answer. Where did you get the Z3 shifter?

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                                #60
                                The selector shaft seal? The one you slide on the selector and tap into the tranny? When M3 Ryan and I were doing my swap he showed me a trick where he just tapped another one on top of the one that was already there. Apparently there is room for 2 to be driven in there. I have no clue how to remove them, but it's working great for me.
                                Last edited by george graves; 03-22-2010, 10:09 PM.
                                Originally posted by Matt-B
                                hey does anyone know anyone who gets upset and makes electronics?

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