Frank Macaluso's E30S62 Swap Thread

[NickL]

Awesome progress and innovation man, can't wait to go for the M60.

[Garageaholic]

I'm still aiming for the end of august to have a complete swap sleeper. I'd like to get it started before the end July. Everything else after that should be a cakewalk.

[golde30]

looks very involved. these kinda swaps dont happen fast unless its some1's full time job to get it done, with unlimited resources backing them up. Even at that it still takes alotta time. That being said, kudos to you for taking it on, cant wait to see it finished!

[Garageaholic]

Next steps are:

Complete Pedal Potentiometer with Cruise Control
Fit engine in again and build oil filter housing bracket
Build wiring harness
Begin fabricating exhaust manifolds.

that's about it!!

By the way, I came into this swap thinking that it would be very straightforward and it would be an easy install in a matter of a couple weeks. I quickly discovered that this is much more involved than the M60 was from every angle. Everything needs to be beefed up, all clearances need to be made with adequate space, and wiring is.....well, to be CORRECT and ACCURATE and to maintain all functionality, it needs to be very thorough and meticulously checked over and over again.

This is not an easy swap. It's very much more involved than the M60.

[Garageaholic]

Updates 6/20

Some updates for the past couple weeks. A lot of fabrication work. I worked out all the wiring, but I have yet to create my harness and test it. That will be coming shortly.



Took the dashboard out for a couple of reasons:

• The harness will fit underneath the dashboard, so there is no way I would have fit it in there had the dashboard been in there.
• Wire up the on board computer MPG adjuster
• EASILY tap into any power, signal, or ground wire that I need to while it's all out.

Too, the 3.15diff out and will be putting in a 2.93 for some lower-rev highway cruising.


I grommetted all of the areas where wires will be going through the firewall. These were seemingly hard-to-find, but I found them online by the foot. I RTV'd it with black sealant to keep it in there.


I decided to make an adjustment for the clutch fork distance. Especially since my clutch was engaging basically right off the floor.









Almost complete... just need to cut the threads down now.


Now I need to drill out the hole and insert a helicoil. Why helicoil and not just tap? Because the hole was too big to simply tap a M12x1.5, which is the size I decided to go with. Check it out below.





After drilling it out with 31/64", I can now start using the special tap for the M12x1.5 helicoil.



Helicoil tool.




Adjustable Clutch Fork Pivot tool ready for install!


Adjusted for more throw:


Back to stock if necessary!


Now I decided to investigate why my clutch was leaking fluid from the upper boot. It started leaking a little bit, but once I loosened the boot, brakefluid came pouring out and even though it was a new master cylinder, I figured it was time to buy genuine BMW and not aftermarket shit.

So this is what I found on the seal after I removed it. no wonder it was leaking slowly.....






So I haven't posted it, but I've been concentrating (preparing) a lot on the wiring and the pedal potentiometer. I decided to mount the potentiometer on the front driver wheel well housing near the brake booster. I don't have pictures yet because it's not yet complete, but with that being said, I wanted to move the cruise control motor and cable to inside the car and I think I found a spot to install it. I'll have to rig up some way to install it easily and with adequate strength.

[Garageaholic]

What a monster this will be! Good job man! Any ideas on the weight difference between the s62 and m60?

I think that the S62 (480lb) is about 20lbs heavier than the M60 (460lb). These are rough numbers.

I think this is because of the extra pumps, VANOS...etc. I have a flywheel that's approximately 15lbs lighter than stock, so that should help!

Frank - you are the man......

btw - all your pictures are missing from your m60 swap thread ;(

Sorry, George. I'd have to check the code! All my s62 pictures now are linked to facebook, so I suspect that i'll never lose the link.

[Turk]

Looking great Frank!

[george graves]

Frank - you are the man......

btw - all your pictures are missing from your m60 swap thread ;(

[MJCRO]

Looks awesome Frank! Slowly but surely man.

[Jean]

What a monster this will be! Good job man! Any ideas on the weight difference between the s62 and m60?

[Garageaholic]

Updates 6/3

some updates today: Got the drivetrain in today. First test fit of 3

First Fit 6/3: Analyze interferences or close contact. Begin measuring for headers. Mark parts of body that need further modifications.

Midterm: Make all body modifications, refine/complete headers

Second Fit (Late June): Late June: Crank Engine with electronics fit. Complete Headers and begin downpipes, midpipes, and muffler. Accessories Test Fit - Oil Cooler Lines, Power Steering, Compressor Test Fit, Radiator, Intake Test Fit. Heater CorePipes

Midterm: Organize electronics, pedal assembly Test Fit the core support. re-Paint Engine Bay

Third/Final Fit (Late July): Aesthetics, Final Exhaust, Body, Drive.

That's all I can think of right now.



It took me over 2 hours to get this to settle in where I wanted it . It's really far back, so I need to make further modifications to the firewall, even though I had the M60 in the car before. This engine is noticeably larger with all the extra sensors, pumps, and that HUGE intake manifold.







Got the ECU back from Adem Ergen at Ergen Motorsports. Thanks!!! He's been a great resource for random help throughout the swap.


And here is a to-do list. This is before I test fit the engine this evening. This list will likely double with all of the little tasks I have to get this engine to sit nice and snug in the engine bay.


I'll have more updates tomorrow!

[M3 euro ltw]

CPS and shells vs bearings

Glad my pointer to you on the CPS helped you out.

Second, people should consider the ARP style technique of getting bolt stretch measured for con-rod bolts.

(UK calls the parts shells, usually in the US, we call them bearings)

At any rate... google or read up on using a stretch gauge to get the exact and proper torque accomplished for rod bolts. It is a rare opportunity to use a stretch gauge since both sides of the bolt are accessible, and move away from any possibility of difference in friction due to contamination, oil selection etc when you use the gauge to put in the bolts for con rods. Those variables can affect the end result vs actually getting the stretch right.

Just a thought. (otherwise, carry on. BTW con rod bolts are often available from affordable places other than BMW specific vendors, and I got my very decent stretch gauge from Jeg's of all places)

Alex.

[Turk]

Hi Frank, Im referring to the shells, They often knock. (ps no email sent just mentioned it here) Sorry didnt mean to panic you, its just good preventative maintenance thats all.

If the car is coming off the road after the summer then you can analyse it all and do the necessary works, good plan.

A friend alerted me to a really good thread of S62 shells being done fyi:

http://forums.m3cutters.co.uk/showthread.php?t=65386

[MT325is]

Frank, get ready to make sell swap write up for this!:) a lot of people i think would be interested.. i sure know i am!

[Garageaholic]

Hey Turk,

I haven't gotten your email yet since i haven't been at work in a day or two. What are you referring to "not an uncommon fault on S62's"? What exactly is the fault you're speaking of?

I checked the engine and replaced the rear main gasket/seal and some oil o-rings. That's just about it. I didn't see any evidence of leaking, coolant corrosion on the aluminum, or any other signs of increased wear or tampering. I think that this is a pretty unadulterated S62.

If anything does come out of the works this summer through regular driving, I will overhaul the engine likely in the winter when I don't plan to drive it anyway.