E30Rossi's Full Build - Overhaul - 5 Lug - Bay Shave - M54 Swap (Pic Heavy)

[Gtfour]

Really nice work/build thread so far!

I just got an E30 Coupe a month ago and I will start a complete restoration on it next winter.

[E30Rossi]

Really nice work/build thread so far!

I just got an E30 Coupe a month ago and I will start a complete restoration on it next winter.

Appreciate that! This is the perfect place for inspiration and to share your own progress! Enjoy the process and welcome to the E30 community!

[E30Rossi]

Back to the progress report!



Started reassembly of the head! All new valve stem seals, lapped the valves, cleaned everything up and reassembled.


Block was cleaned as much as possible



New bearings and OEM hardware, crank back in

[E30Rossi]

Honed cylinders, ready for reassembly!


Nice cross-hatching


New OEM main bolts


Pistons installed with new piston rings


A/C Delete Plug from Falk Manufacturing. Really need to clean this fresh paint soon..

[E30Rossi]

Quick refresh






Much better!

[E30Rossi]

Crank bearing gets a fresh coat of paint as well




Vanos unit looking way better


Timing cover fresh and new


Rear main cover freshened up as well

[E30Rossi]

Baffle was sandblasted, with all new hardware



New Elring headgasket


Head back on, Timing coming together


Took a few times to get the timing right!


So fresh and clean

[E30Rossi]

Happy we took the time to do the extra steps of rebuilding the motor!


New Oil Pump Chain


SAP Port Blockoff Plate


E38 Oil Pickup Tube installed


Bought the Vanos /timing kit on amazon and very satsified with the quality!

[E30Rossi]

My OCD kicked in once again. Couldn't stand putting the motor in looking like this


Ignore the tape job, I did with what I had left :P


1st coat already so much better


Valve Cover hardware gets a refresh too!


MUCH better

[E30Rossi]

New OEM tensioner installed



ICV Ports plugged in intake for M50 Manifold


Timing cover installed. Engine looking soooo fresh


Worth the effort!

[E30Rossi]

Crank pulley installed, and torqued to 302 ft-lb
rebuilt Vanos unit installed


New sparkplugs to go in


Valve Cover, new Thermostat and new OEM waterpump


ECS aluminum Waterpump pulley, powdercoated engine mount arms, new sensors, new OEM heater pipe


ActiveAutowerke headers fitted and looking AMAZING

[E30Rossi]

Looks factory fresh with beauty cover


Way too excited to see this in the car!



My steering linkage had a loose in it, so went with the CondorSpeedShop linkage! feel super smooth, and that means steering is officially done!


Love seeing parts going back and finishing off systems

Suspension, Brakes and Steering all done now!

[E30Rossi]

Back on 4 wheels and can actually move it around and steer now! That's an accomplishment in my book


I received the E34 oil pan with the VACMotorsports baffle already welded in, but as you can see the welds were horrible and actually loose.
Got my buddy to weld it in properly so it's solid


Rebuilt alternator to go with the refresh vibes


ChaseBays vanos line installed


Oil Pan installed as well as Revshift 24V Engine Mounts. not a fan of the green...

[E30Rossi]

Oil Filter Housing gets a coat obviously


Matches the engine, we can move on!




Starting to look pretty complete


Next up!

[E30Rossi]

Belt tensioner, idler pulley, alternator installed
just missing the power steering pump bracket to be able to install the pump and belt!





Oil Pump Nut welded on