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Stock m40 318i to 2JZ Greddy single turbo E30

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    Stock m40 318i to 2JZ Greddy single turbo E30

    Hey guys, yet another life long E30 tragic here. Have been playing with them for as long as I can remember and thought I'd show you my latest project that should be fairly relevant to anyone who likes fast E30's.

    I've had a turbo 2.7 M20 e30 for quite some time that has been built up and stripped down and to be honest I got disheartened with e30's for a bit (I also switched camps with the purchase of a 1972 300sel 6.3 which didnt help) until my sister decided she no longer wanted her 1989 S2 318i E30 coupe. Sweet, got me another daily to tinker with cheap. Except the motor had some cooling issues that needed to be sorted out. No big drama.

    While I was getting stuck into that a 2JZ with a manual box and Greddy turbo was thrust under my nose with strict instructions to buy it and fit it to the e30.

    What could I say? I had christmas holidays and the cash, so thats exactly what I did with the help of a good mate who runs a workshop specialising in conversions. So in a little over a week, this happened.......

    (This has been cut and shut from a couple of other forums so forgive me if it seems a little all over the place)

    Enjoy!

    My sister decided she didnt want her 1990 S2 e30 coupe and promptly deposited it in my front yard with a wheezy stock M40. I was just going to drive it around as such but some minor cooling issues caused me to crack the sads and embark on something with more grunt.

    Enter Toyotas almighty 2JZGTE :D

    Pictures and stuff cut and pasted from the now infamous Performance Forums.

    Enter project free30:


    1989 s2 318i e30 coupe in Alpine white with a nice set of Racing Hart Monoblock 17's after a decent scrub.



    Being a chicks car it was fairly scruffy when I picked it up. Hadnt been washed in years, interior was grubby as sin and generally not particularly well looked after.


    Pretty filthy under the hood as well and running like a POS. Previous owners had spent some coin on it though. Has extractors and full exhaust, lowered kings and some other bits here and there.


    First mod was to replace the cracked and rooted inlet pipe that was causing the car to not idle and generally behave like a shitbox. One silicone bend from supercheap and some drilling and cutting to mount the air idle control pipe, voila perfect runner. Remounted the fulsik pod filter as it was laying in the engine bay, not connected to anything. chicks :upset:rolleyes2


    Next mod was rimz yo. Had these to put on my turbo e30 but couldnt resist :)




    Then I had to test the stock engine for final effectiveness before its removal:
    (hopefully youtube stuff can be embedded here)


    then got down to the job at hand


    Ever increasing pile of unneeded shit



    Going...



    Gone. No more wheezy 4 banger skids.



    Hopefully one day soon.



    Yanked the covers to check for awesomeness. Had it in spades. Motor had done 90 thousand kays and had obviously been recently serviced as it was sporting a new timing belt and was nearly clean enough to lick inside. Just like your mum.




    Parts donator donk came with a great condition OS Giken twin plate. Wont fit without a 600 dollar flywheel though and will probably kill the box the way I drive so its getting diced.



    Also came with this



    So in the end this



    plus this



    equalled this



    :D

    Next up, finishing mounts, working out the braking system and start on piping for cooler and exhaust.

    3" mandrel bent steel for the exhaust, stock but new e30 325i radiator and some Aussie BA Falcon engine mounts to replace the weeny e30 items.




    2JZ traction control deleted and throttle shortned to suit, 2JZ sump sectioned to fit over e30 crossmember (which probably wasnt needed) and adapter manifold made up to suit the Greddy turbo from the stock cast manifold. Short, tight for maximum room and spool.




    Engine and gearbox mounts sorted. BMW thought well ahead with slotted rails for the various gearboxes used in the e30 range. Made our job so much easier.


    Exhaust sorted, adapter manifold takced together, dump pipe done and turbo mounted


    Stock wheel was shit. Yanked it and fitted a momo I had lying around


    Engine mounted and sorted. Engine mounts are surprisingly simple and beefy as **** :)




    Exhaust finished manifold to tip and turbo mounted. Spent some time porting the stock manifold and steampipe mini manifold today. **** of a job, will not do again F------------- (porting was easy, picking metal shards out of ******* everything was a ****)





    3.45 LSD from my other turbo e30 fitted for extra hektikness


    Al spec cut and shut sump to clear cross member


    Paint stripping the cam covers to repaint in crackle black



    Ginning around with oil lines and shit


    Disassembled the front end and hacked shit up with the airsaw to start fitting the cooler and piping



    Coming together nicely. All smiles.


    Next up, cooler mounting and piping, finish oil and power steering lines and fitting new coils and shocks to replace the old busted shit.



    Updates are useless without pictures so here goes:

    Wiring happening:



    Box of excess crap from 2JZ and BMW loom



    While this was happening I painted the inlet manifold and rocker covers




    and cut the trans tunnel to suit the new shifter location


    Shifter installed. Looks factory.


    Modified power steering to suit BMW lines. Another factory installation.


    Power steering pump originally had all this crap hanging off it, including an air bypass to bring the idle up when the pump was being operated. Brazed up the factory line, ditched the air bypass and plugged the factory BMW line in with factory banjo fitting.
    Last edited by sketchypip; 01-08-2011, 04:56 PM.
    1989 318i coupe, 2JZ, 380rwhp

    #2
    So more pictorial updates from yesterday:

    Cooler piping and inlet is now done, save for some clamps and one welded connection


    Painted the cooler black and popped it in. Stealth is the key.


    Some better shots of the steam pipe adapter manifold that Al knocked up off the stock cast item. Thousandsly easy and compact, surprised more people havent done this. Will spool hard too given the short length and smallish diameter.



    Power steering resivour adapted and fitted. Stock BMW one sits where the brake booster and master will be going so had to be turfed. Popped a random item (subaru/landcruiser maybe?) down near the headlight out of the way.


    Clutch sorted and working, if a little heavy. Just plugged the factory BMW line onto the R154 slave and BLAM! one working clutch :)


    Got the dump pipe wrapped to protect the wiring loom sitting above it. Will probably get this HPC coated at some stage in the future. Handy hint, if you are wrapping stuff yourself soak the wrap in water so it grabs onto the pipework better. Makes things much easier.



    Dump reinstalled
    Last edited by sketchypip; 01-07-2011, 03:12 AM.
    1989 318i coupe, 2JZ, 380rwhp

    Comment


      #3
      Damn now thats a swap worth doing. did you make the motor and tranny mounts yourself?
      Originally posted by blunttech
      r3v does not fuck around. First you get banned, then they shoot you

      Comment


        #4
        Brought up suspension from my other e30, Koni adjustables, king springs, ATE power discs and some good pads. Will fit them at some stage soon.


        Fitting inlet manifold


        Looking good




        Fitted cooler and started working out the piping



        Starting to look like shit is actually going to be driving soon


        As Al would say, "Yeah dawg!"




        Killer end to 2010 :)

        At this point I have to thank Al from AM Auto at Noosa for his expertise and motivation on this project. There is no way known this thing would have come together so quickly and easily without his knowledge and skills and can not recommend him enough if anyone is looking to perform wacky conversions and make shit skid. Cheers bloke, much appreciated.
        Last edited by sketchypip; 01-07-2011, 05:03 AM.
        1989 318i coupe, 2JZ, 380rwhp

        Comment


          #5
          Next was the issue of brakes, and its one that has left us scratching our heads since we first started the build. Al did some measurements, looked through his pile of unused crap and came up with a solution. A Gemini booster (quite fitting seeing as this car is just a german gemini) with a Subaru 1 1/16th master cylinder. Will probably have a fairly hard pedal to being with but once I chuck some decent 4 pots on it should settle to a fairly nice modular pedal feel with any luck.


          Painted that too in preparation for fitting


          Now to make it fit which was the hard part. The whole shebang would fit if it was moved over about 50mm from the existing setup. So that's exactly what we did.
          After lots of measuring another hole was cut to fit the new booster actuator rod and mounting holes for the new booster.


          As you can see there is fark all room to play with



          Test fit one. Master sits hard up against the strut tower side brace. Not ideal.


          Hey presto! All of a sudden we found more room. Dunno how this happened but it did not involve a hammer or swearing. Promise.


          Fits like a finger in the bum.


          Next up was to make a plate to cover the existing booster hole and give the new setup some more ridigity as the firewall in this section was made from cheese and failure. After much scouting around and thinking about cutting up parts of the shed (basin doors, roll cab shelves, Cr****a) Al set off to his neighbours place and came back with a chunk of 100mm RHS steel. Into the vice, cut, hack, chop, and grind and out comes exactly what we need.


          Rinse and repeat for the inside and fit


          You'll notice the inside peice has been welded to something else. This is the factory BMW lever actuator for the stock booster/master. A small exentsion will need to be chucked in to get this working with the new location, but isnt a major issue.


          Helper dog helped

          Last edited by sketchypip; 01-07-2011, 05:05 AM.
          1989 318i coupe, 2JZ, 380rwhp

          Comment


            #6
            God damnit, I fucking love Australia.

            Comment


              #7
              where in brisbane are you at??

              Comment


                #8
                Good job boys show em how its done!!!

                Comment


                  #9
                  Originally posted by J3M93 View Post
                  where in brisbane are you at??
                  Northside mate, but the car is in Noosa currently. Will be back here at home as soon as I shift my other e30 shell so I can stick it in the garage with the 6.3.
                  1989 318i coupe, 2JZ, 380rwhp

                  Comment


                    #10
                    Some more pics of the initial brake booster/master setup and general engine bay being put together. First setup didnt work as the pivot point was kept in the factory spot and we just welded a tab to operate the new booster. Turns out this is a no no as the pedal effort increases ten fold and the car feels like it has no brakes. Back to the drawing board.....




                    Radiator pipework, filler point (an old A/C condensor from memory with a billet filler neck and cap welded on) and plumbed.


                    Cooler painted black and installed.


                    Starting to look like something


                    Al tig welding up the only welded joint in the cooler piping. Pro job as per usual.


                    Subaru brake line splitter installed to get all brake lines working as they should.


                    Brake booster and lines sorted and in their final home. Al sprayed some black paint to cover some of the bare metal left when "clearancing" the strut tower brace required for fitting the master. Engine bay will get a proper cleanup and paint touch up at some stage.


                    The modifed (yet again) booster pivot arrangement. Added another pivot (and deleted the existing one) directly in front of the booster to give maximum leverage and much better pedal feel. Al got photography lessons from edo :D



                    While Al was under the dash doing this I got stuck into refitting the front end and tidying up as much as I could in the time that I had. Gave all the black plastics a rubdown and dust over with bumper black, makes a huge difference.



                    Can anybody say stealth?


                    Completed engine bay shot, now with washer bottle, radiator overflow and all hoses,wiring and other goo connected and working.



                    So there you have it, from stock 318i to 2JZ fire breathing monster in just over a week. Brakes are on the cards this weekend as we have just about devised a front setup using Nissan 4 pots and Chrysler Voyager 305mm rotors with the required caliper adaptors on the cheap (may even look at selling a few as a kit because it should be *farking* cheap) and finally fitting all my spare suspension. If the brake setup doesnt do what I want it to, a set of IE wilwood 6 pots will be on their way chop chop.

                    Also to come is fitting the Walbro intank fuel pump (being a pov spec 318i it has no external pump), fit my good Recaro interior, some strut braces and sway bars and possibly a full set of Defi guages if I can do it nicely.

                    Enjoy :D I know I will be.
                    Last edited by sketchypip; 01-07-2011, 05:12 AM.
                    1989 318i coupe, 2JZ, 380rwhp

                    Comment


                      #11
                      hey keep us updated on the rotor and caliper combo, sounds like it could be a good one

                      Comment


                        #12
                        Can't wait to check this out when I get home, all the pics are blocked here at work.
                        Need parts now? Need them cheap? steve@blunttech.com
                        Chief Sales Officer, Midwest Division—Blunt Tech Industries

                        www.gutenparts.com
                        One stop shopping for NEW, USED and EURO PARTS!

                        Comment


                          #13
                          I love australia.
                          Originally posted by TSI
                          ♫ Rust flecks are falling on my head...♫
                          OEM+

                          Comment


                            #14
                            Holy shit, talk about turning the suck off, and cranking the win to unbareable levels.

                            Looking forward to some sick nasty vids man. Congrats on the beauty. Sick

                            Scientists have proven that the average human being gives 60% too much of a fvck about most daily
                            activities, so stop giving a fvck, and drastically reduce your capabilities of giving a fvck

                            Comment


                              #15
                              epic

                              Comment

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