Project M42 Touring..Update-Feb 26-E30 M3 Tacho...

[MikeDE]

Sorry for the long wait....

Went at it yesterday and had an 'oil pump' issue http://www.r3vlimited.com/board/showthread.php?t=213067 ...I had to order the skinnier pump:


And here it is installed:


And the new cover tq'd down:


And the timing case cleaned up a bit, and tq'd to the block:


And the updated oil pressure relief valve:


This is how I compressed it to get the snap-ring:

I leaned on the towel/driver/extension to hold the spring, then jimmy'd the ring into place.

Upper Pan and pickup in place, sealed, Loctite'd, and tq'd:


Lower pan tidied up a bit:


And sealed and tq'd, along with the Oil filter housing:


That's it for today, I will try to clean the head tomorrow morning and get it bolted on this week.

[MikeDE]

Well, it's been a few weeks since the last update...

I had gone back to the dealer to borrow the E12 again, but they lost it. Soooo I had them order one for me from BMW. A week later, here it is:

And only 29euro.

I torqued the head down in accordance with the manual, threw on the lower intake manifold, changed the upper and lower injector o-rings and the rotted fuel lines on the feed/return pipe. Installed the new guide on the oil filter side, and the old upper and lower guides while they were in excellent shape.. Separated the Header & cat pipe, and temporarily hung it on the motor to get it off of the floor. The new studs and nuts will be in tomorrow afternoon:


You may have noticed that I am missing some timing components, well, the PO made some kind of Frankenstein-mutt-bastard-timing setup on this bitch. It is an M42 timing case, I know I know, 'but it has a deflection rail instead of the time-bomb-make-whole in your wallet when it explodes Idler gear, BUT if you check realoem.com, you will see that the (Europe) E36 M42's produced from 9/93-9/95 according to the pic, have the deflection rail. This is why mine did not accept the later, thicker M44 pump, b/c it is in fact an M42 case.

Here is one issue I ran into:

On the right is the M42 guide. I ordered the M44 guide by accident. At the time I hadn't even removed the oil pump yet so I was unaware of the 'late' M42 timing case. Soooo, I ordered the Bushing/bolt/washer from the dealer, they should be in by Tuesday. Oh yeah, the bolts only come in qty's of 10!!

And I ordered a COP kit, so these go bye-bye:

Can anyone tell me, startiung from the top left and going clockwise, which cyl each lead goes to?? Thanks.



So, being fed-up with staring at that goddam motor, I turned my frustration on the Transmission.


First, I had to drain the fluid, but I have no 17mm wrench, but I have a Pipe wrench, leverage and a wheel-bolt:

A word to the wise, always undo the filler FIRST^, then thre drain:


And some new parts(among many others) I picked up from Mr. Blunt:

Except for the slave and line, I bought that from another member along with a Never installed Massive Hartge/Mtech/whatever-style dead pedal, a Whore-and-a-half to install over carpet but I'm happy with it.

The old pivot worn to a nub:



And lastly, can someone give me a part no on this pc:

I have no VIN for the car I grabbbed the motor out of and realoem has 2 different numbers and the pic doesn't coincide, thanks.

Stay tuned for more pics in the next week, My wife is taking the kids to the North Sea for about a week, so I will have some time to get some shit done. In the background above, thew yellow springs are the KW 40/40's I just picked up. I also verified that in fact I have a full set of Koni SA's to go with them, already adjusted. I also picked up a set of the Goodridge SS brake lines from Blunty as well, they will be going on this weekend possibly. If I can sell some shit, I will also be ordering the Massive Street kit for the mofo.

:finger:

[SkiFree]

Probably a little late now but......

What were the part numbers listed on realoem?

[MikeDE]

Probably a little late now but......

What were the part numbers listed on realoem?

Yeah well, if the origianl lasted this long, then the new OE will be ok for the next few years.

As for the brake hose/valve, the booster hose that is currently on my Touring is ok, so i'll just swap the valve to the m42 unit. The current one had a 90deg angle to it.

So anyway, made a little progress after having to wait over the weekend for parts:

New studs, the come in packs of 20, f***ers.


I love the look of the new bolts, but these don;t come in packs of 20. They come in packs of 30.:finger: you BMW.


Lower intake was done last time, but I picked up a bunch of fresh clamps and secured the fuel lines, popped on the upper intake and TB.


Where I left off.

I also got the bushing for the later style tensioner guide, BUT i'm still waiting on the washer, it never got ordered.


I also ordered all new hoses for the 'mess under the intake manifold', why you ask?? Because 1) I don't have the patience to futz around making the hoses fit/not rub on anything/find vacuum issues later, and 2) I am keeping my TB heater element. We get some crazy weather here in Germany. That plus sustained Autobahn speeds in cold weather are mroe likely to cause issues. And by the aformentioned speeds, I will most likley be switching to a 4.27 so I won't be traveling faster than 130km/h(80mph) for extended periods. But nonetheless, it is one more thing that I don't want to worry about.

And I forgot to mention, one of my front KONI's are shot. So I picked up a set of New-in-the-box Bilstein sports. And BTW, if anyone has a new set of E30 M3 sway bar tabs w/ or w/o links, I want them, lemme know.

[MikeDE]

Well, it;s been a while since the last update. I've been working like a dog and no time to take pics.

Here is my work area, it's the in-laws driveway:


I pulled the M40 this morning:


The M40 is sitting on the legs of the crane, and the m42 is in the foreground:


The new crane I bought was to shallow to get all the way on, so my valence incurred some damage:



Tomorrow, I plan on pulling the E30 rack and installing the E36 rack I have sitting around. I picked up a Zionsville autosport lnkage shortening kit, and will be ordering new tie rods Monday.

The M40 exhaust doesn't fit on the M42 cat-section, soi I wll be ordering a new exhaust as well.

Till then....

[Simon S]

Nice work as always Mike.

Can anyone tell me, starting from the top left and going clockwise, which cyl each lead goes to?? Thanks.

Here’s how they were on my m42:
Note numbers on stock coil cover.




Corresponding cylinders labeled.

[MikeDE]

Thanks Simon, but I have already pulled the connectors off like a meathead. Then this made me feel so much better:

But since the wires are frozen into position on the harness after 20yrs, I have a good idea of where they go.


So I started here this morning AFTER going to the parts store to order new complete tie rods and an original catback. There is no chance in hell that the M40 catback fits the M42 cat.
Fresh FW bolts & pilot bearing:



Unfortunately, I have an unhealthy hole, in my crankshaft. It's fairly tight but not as tight as I would like. The other 7 were perfect though.

Clutch disc and PP clean and ready for reinstall. I cut the glaze from the FW & PP with a die grinder and brown disc.


My Ghetto-Motorsports Kupplung einstellung Werkzeug. It got me part of the way there. But I ended up eyeballing it, then tightening the PP just enough so the disc could still move a bit. I jimmy'd the tranny on, then gently pulled it off. I torqued the PP bolts with fresh hardware, and the trans slid in nicely.







Wiring harness and exhaust manifold on. I had to remove it for transport...on a dolly, about 7/10's of a KM from my in-laws, on a Sunday Morning. Working in Germany on Sunday gets you more dirty looks than you can imagine.


Old leaky rack out, and subframe cleaned up a bit:


Old dirty E30 rack on the rt, new old dirty E36 rack on the left:

And don't start that 'why didn't you do a Z3 rack?!' shit...3.2 is better than 4.0 on the E30 rack, a 20% difference. Plus, I have had this rack lying around for over a year and now I have a chance to put it in.

I cleaned it up a bit after I have it in the car(no pics)

Picked up a Zionsville E36 rack spacer kit from another member here in Germany. And a new giubo from Sir Blunt.
Removing the old rivets first:


Tah-dah, I didn't break anything:


All back together. It's not tightened, most of my tools are at the worksite.



To the shifter rod, old bushing was all nasty and soft, and oozing fluid:

Knocked that bitch out with a screwdriver, lubed the new one with some all-natural Bio homemade lube I whipped up then pressed it in with my good old bushing-persuader:



As I was looking at the rear shiftrail bushing, I realized that there was too much free space in there, which equals unwanted shifter slop.


SOOO, I so happened to have an old pkg of 5 min Epoxy, so I mixed that nasty stuff up:


And filled the offensively large void, rear first of course:

Yummy.....

Then I spent the rest in the front, but there wasn't much left given that the rear was so cavernous:




AND that all for today, dealer trip tomorrow as the numbnut gave me the wrong crush rings for the PS lines......aufwiedersehen.

I also ordered the 280x22mm Massive Street Kit, and Billy Sports to go with the KW springs. I will be installing the Goodridge SS lines on the rear when I drop the subframe to fix my Shifted 1yr old bushings. The fronts will be waiting for the Wilwoods.

[MikeDE]

Today was my B-day so I didn;t get much done. I was up early, had breakfast with the Wife and Kids, then ran around picking up my last few parts I need for the swap. picked up the m42 catback and complete tie rods, and new crush washers from the dealer. He very kindly swapped the (2) wrong sized washers for the correct ones.

One hurdle I was worried about the last week was the Center support sleeve on the front of the driveshaft. For those of you unfamiliar with this little whore, it sits in the very front of the driveshaft and centers the trans output shaft so the giubo must only deal with rotational forces rather than also having to hold the DS straight, or so I think anyway, don't quote me. On anf off for the past week I tried beating it with a slide hammer, them this morning I took it to a local shop. He tried heating the bitch, then with the slide hammer, but only succeeded in burning the rubber out and stinking up his shop. So I took it back home.....Just a few minutes ago after the kids went to bed, I wanted to see how 'hard' the sleeve was. To my surprise, it was fairly brittle and easy to cut through. With little stroke available, I locked a Metal-cutting keyhole saw blade in a pair of vice-grips and started cutting, 10 minutes later I had this:


Then instead of taking my BFH and driving the new sleeve home, i opted for a more civilized approach:


All good in da 'hood:



I also highly recommend this mod here, to rejuvenate your sloppy hole:




It is very tight and slop-free, I can't say for how long though.

Tomorrow I plan to have the motor in and running.......

[glucklich21]

I have a stupid simple method I used for getting that sleeve out. It takes 10 mins max. I'll post a pic when I get home from work as a FYI for others. ;)

[glucklich21]

Here's what you do to get that out. I'm going to figure you saw that the back is metal, not rubber. That will give you enough resistance to push the bushing out from the backside instead of pulling from the front. I used an old drivetrain bolt, a hammer, and some wet newspaper. The bolt compacted the newspaper to the point it had no where to go but out. So you keep forcing in newspaper as it slowly pushing the bushing out for you. Mine took less then 10 mins.

[MikeDE]

Thanks Macgyver, I wasn't expecting that.

[monty23psk]

Nice progress. Was wondering one thing, why did you use a steering knuckle from an non-airbag car?

[glucklich21]

Most euro spec E30s don't have airbags.

[monty23psk]

Correct, but in the picture of the engine bay, it looks to have the same knuckle as mine which is the one for the airbag cars. Thats why I was asking.

[MikeDE]

Nice progress. Was wondering one thing, why did you use a steering knuckle from an non-airbag car?

Had to I guess, this is the way i've seen it done so many times. If an Airbag knuckle fits with a NON-airbag column on an E36 rack w/o modification then I would do that in a second.

Here is today's progress:

Cleaned the rack up a bit, got the knuckle in, and aligned. The wheel sits straight and the rack is centered. New complete tie rods installed. FYI i'm using an E36 325i rack, E30 tie rods, E30 lock plates(not the best with this but they work) and Loctite Blue. For the knuckle, us-spec non-airbag w/ Zionsville E36 rack kit. A small amount of clearancing was required in the upper knuckle to stop the binding. Oh yeah, new steering giubo also. I'm gonna eyeball them when I get them wheels back on, then after a test drive i'll make adjustments.


Got some E21 mounts. I had to enlarge the holes in both the trans brace and trans to accept the M10 studs on the mounts.


No time to take pics while the motor was on the crane, but it's in...with a little help from my Father-n-law. I had to remove the pass side mount to drop it far enough to get onto the drivers side mount. I was then able to lift the motor enough by hand(still hanging from the crane of course) to slide the other mount underneath.



Checking continuity to determine which lead goes to which coil for the COP conversion:


I got a bit further and plan to fire the bitch up tomorrow....still have to bend the steering HP hose, mount the ECU, fluids, bleed the slave cyl, yada yada.