Here are some updates on my "ultimate daily driver" build.
I spent a lot of time cleaning parts. The Gunk multi-surface cleaner seems to work pretty well. I didn't want to use anything too harsh like the purple cleaner that will etch aluminum.
I removed and painted the coil pack brackets from the 318i. I thought about using the M44 coil pack or going COP, but I'm going for an OEM look. They are held to the car with spot welds so I just had to drill them out. Then I riveted them to the coupe.
It was quite a job converting the Z3 M44 harness (top) to resemble the E30 M42 harness (bottom). I was able to fit the firewall grommet onto it without damaging it. All I needed to do was take the cover off the ECU connector and carefully slip it over.
I replaced the 3 seals on the G240 gearbox and the rear crankshaft seal on the engine. I made a tool to hold the flange steady and shaved down a 30mm impact socket to fit the nut on the output shaft. The crankshaft seal came pre-installed in a new cover from BMW.
I installed a new LuK dual mass flywheel and Sachs clutch. I know a lot of people go the single mass flywheel route but the M40 or Valeo flywheel with clutch are only about 2 lbs weight savings over the DMF. The DMF will reduce torsional vibrations to help protect the drivetrain and allow a more comfortable daily driving experience.
I installed the E30 M42 oil pans and I bent the dipstick tube to go around the serpentine belt tensioner using a conduit tube bender. I had to shave some material off the side of the alternator bracket and tensioner bracket too. I bolted it to the lower bolt on the alternator bracket. I sealed the pans with new gaskets and Dirko on the block side and Curil T on the pan side. Hopefully that will prevent leaks.
A friend helped me weld up the exhaust. I used the M44 exhaust manifold, but I had to use the front section of the E30 M42 exhaust to clear the control arm bushing and we connected that to the Z3 cat and center muffler followed by the new rear muffler. I also installed a 4.10 torsen LSD from a 2000 Z3 2.8.
Some other things I've done were installing new Sachs front struts and the M42 springs (which happen to be the same as the M3), the Z3 1.9 steering rack (I made a new plate for the steering column through the firewall), and the Z3 1.9 shifter.
I spent a lot of time cleaning parts. The Gunk multi-surface cleaner seems to work pretty well. I didn't want to use anything too harsh like the purple cleaner that will etch aluminum.
I removed and painted the coil pack brackets from the 318i. I thought about using the M44 coil pack or going COP, but I'm going for an OEM look. They are held to the car with spot welds so I just had to drill them out. Then I riveted them to the coupe.
It was quite a job converting the Z3 M44 harness (top) to resemble the E30 M42 harness (bottom). I was able to fit the firewall grommet onto it without damaging it. All I needed to do was take the cover off the ECU connector and carefully slip it over.
I replaced the 3 seals on the G240 gearbox and the rear crankshaft seal on the engine. I made a tool to hold the flange steady and shaved down a 30mm impact socket to fit the nut on the output shaft. The crankshaft seal came pre-installed in a new cover from BMW.
I installed a new LuK dual mass flywheel and Sachs clutch. I know a lot of people go the single mass flywheel route but the M40 or Valeo flywheel with clutch are only about 2 lbs weight savings over the DMF. The DMF will reduce torsional vibrations to help protect the drivetrain and allow a more comfortable daily driving experience.
I installed the E30 M42 oil pans and I bent the dipstick tube to go around the serpentine belt tensioner using a conduit tube bender. I had to shave some material off the side of the alternator bracket and tensioner bracket too. I bolted it to the lower bolt on the alternator bracket. I sealed the pans with new gaskets and Dirko on the block side and Curil T on the pan side. Hopefully that will prevent leaks.
A friend helped me weld up the exhaust. I used the M44 exhaust manifold, but I had to use the front section of the E30 M42 exhaust to clear the control arm bushing and we connected that to the Z3 cat and center muffler followed by the new rear muffler. I also installed a 4.10 torsen LSD from a 2000 Z3 2.8.
Some other things I've done were installing new Sachs front struts and the M42 springs (which happen to be the same as the M3), the Z3 1.9 steering rack (I made a new plate for the steering column through the firewall), and the Z3 1.9 shifter.
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