Brilliantrot 24v swap: BACK UNDER THE KNIFE!..Now with puppy content

[E30STU]

subscribed.....

[TeXJ]

Thanks! I have a m52b28 swapped obd1 car with no chip and thinking I need one to complete the swap.

[Nick_S]

Just read through your whole thread, really cool build! Also very simalar to my m54 build. I'll probably use some of your tips and tricks. :)

Thanks man! Happy to help!

Is yours OBD1 or 2? If OBD1, do you have it chipped and if so which chip?

OBD1 and yes it has a TRM chip. I've ran it back to back with a stock 403 and my chipped 403. The difference is quite noticeable, especially in the mid to high RPM's

[TeXJ]

Is yours OBD1 or 2? If OBD1, do you have it chipped and if so which chip?

[maxpostma]

Just read through your whole thread, really cool build! Also very simalar to my m54 build. I'll probably use some of your tips and tricks. :)

[Nick_S]

I never updated this thread. After chasing an embarrassing issue for over a month. Car is back on the road and running and driving great. I ended up accidentally installing the crank pulley one full bolt hole off...yes there is a guide pin, yes I somehow still installed it wrong, yes I'm a moron. Oh well it's good to go now. After sorting everything out, I installed some Condor solid 24V engine mounts and poly trans mounts. I'll be honest, it might be a bit too much for me. It's not a track car and it's not daily driven but I'd still like it to be tolerable to drive so I'm going to swap the factory trans mounts back in.


First time out of the garage in 2 months.



Trans mounts



Engine mounts and steering coupler.



Shop



I had a few people ask me early on in this thread how I got the wiring to fit under the covers and never ended up getting a picture of it till now. Took a few zip ties, a bit of finagling and tucking wires around but it all fits pretty well with minimal trimming to the covers. Even managed to get the relay's to sit well in the factory holders.





Hopefully I don't have to do anything else to the car for awhile. It had troubles most of last year so it sat a lot more than it didn't. It's getting a suspension refresh but hopefully that be a weekend of work and not end up being a giant project.


Just to recap, here's a list of what all was replaced/upgraded in the last year:

• master cylinder + all lines
• rubber seals in reservoir
• slave cylinder + UUC stainless line
• Valeo single mass flywheel + M42 clutch/PP
• Input/output shaft seals on trans
• all shift bushing + condor solid rear carrier bushing
• oil pan gasket + oil pan (after smashing it)
• Red46 skid plate
• Rear main seal/crankshaft seal
• Pilot bearing
• All rubber fuel lines in engine bay
• Intake manifold gaskets
• fuel injector o-rings
• Vacuum lines to IAC
• Idle control valve (used)
• Crank Position Sensor
• Front Brake calipers rebuilt
• Stainless brake lines + ATE fluid
• Hawk HPS pads
• Brembo blank rotors
• Royal Purple fluid in trans and rear dif

Later this week a new Bosch fuel filter and spark plugs going in as well as a air filter cleaning and new ground straps. Exhaust needs some work but it can wait a bit and I'll pay someone to do that.

[Nick_S]

Little back track post. Sunday my buddy came back down to help put the engine back together and in the car. First I gave the bay a mild clean/wipe down.





Quick clean on the inlet/outlet for the heater core.



After a quick looking over and double check we mated the engine and transmission back together. I ended up buying almost all new bolts to secure the trans as the old ones had seen better and figured why not.



New exhaust gaskets ready to go.



And 20 minutes later, back home,



Got the engine all put back together and realized I forgot to get fluids and I didn't feel like going to walmart to get oil at 1030 at night so I let it sit.


Flash forward last night and I filled the engine and transmission. Tightened up all bolts and turned the key. First it sputtered a bit, then the battery died so I had to pull my truck around to jump. After a loose fuel line was tightened (not before spraying fuel all over), it fired right up. Wasn't idling great but also its been sitting with the engine out for a month. Didn't run it long as the radiator wasn't hooked up but I just wanted to make sure the starter engaged and everything seemed to be fine. I'll wrap it up in the next couple days. Really I just to need to bolt the driveshaft back on and double check all the bolts and it'll be good to roll.


Also here's more puppy content.

[Nick_S]

Car fired back up tonight! Quick check seemed to have the clutch feeling and working great. Radiator wasn't on so I only let it run for like 30 seconds. I'll have it back on the road this weekend.

[Nick_S]

duuuuuude

puppy and delrin bushings? This build update just got way cooler

Haha well hopefully the next one is the puppy sitting in the car while it's moving on it's own.

[wworm]

duuuuuude

puppy and delrin bushings? This build update just got way cooler

[Nick_S]

UPDATE:

Been slower moving than I wanted this past week. We got this little monster and my evenings have been filled with watching this idiot run like a madman around my house. She's a 9 week old Pit/Boxer/Heeler mix.



I did manage to get a bit of work done despite the madness. The remainder of my parts showed up early this week. Key being the single mass flywheel conversion kit from Valeo. The rest of the gaskets, seals, bolts and bushings came in from Pelican and Condor as well.


Parts!



Rear main, crank shaft seal, exhaust gaskets, fuel filter, steering coupler and carrier bushing.





I opted to use the Sachs TOB I ordered rather than what came with this kit as it looked and felt a bit cheap.

Rear main and crank seal all buttoned up. I made a mistake installed the new crank seal and pressed it in too far. I had to very carefully tap it back with a punch and hammer. Nothing appears damaged but I'm slightly concerned it may leak again and I'm NOT interested in doing this much work again anytime soon. Might buy a new seal just for ease of mind. Before I put the engine back in my buddy who helped pull it is going to proof my work as he's an ASE master tech. I'm mostly confident though and went ahead and re-installed the the flywheel/clutch.



Flywheel torqued to spec. 77ft/lbs.


Clutch disc aligned.


Pressure plate installed and torqued. I found some conflicting info on what the spec is but after some digging I found it was dependent on the grade of bolts you use. Since I have 8.8, 18ft/lbs is what you need.




From here I moved to the steering coupler. After marking the shaft and coupler to ensure it went back on where it came off, I ground off the rivets, drilled the holes slightly larger to accept the new hardware and bolted it all back together. It was comical how wobbly that factory rubber piece was .



Next I burned out the factory bushing for the carrier bushing and installed the new Condor one. Forgot to snap a photo of it installed but you can use your imagination.


I still have to do the output shaft seal on the trans but I'm waiting on a friend to machine my 30mm socket down to squeeze in there. Otherwise the main work is done and all that's left is some clean up. Need to clean the bay, replace a few fuel lines I can easily reach now, clean and flush the radiator and bolt the engine and trans back together. I also bought some cloth tape to clean up the engine wire loom a bit.

Hoping to have this back in Sunday or early next week. Excited to drive this again with a properly working transmission and freshly tightened up!

[Nick_S]

great work! I feel like down the road you're going to wish you went with a LWFW. Especially with rev matching and low end engine speed. I'm probably projecting, but it's def one of those things I wish i had done while i could.

Thanks man! I wouldn't mind one but I have been driving 5 years on the stock one and it's been fine. I just got a single mass OE replacement and it's about 7lbs lighter so while 22lbs isn't light, it's also not that heavy. Should be noticeable. I had an 11lb Fidanza flywheel on my old supercharged SVT Focus and it was a rev happy SOB. It did make daily driving a tad annoying as it would drop revs super quick and in town driving and stop and go would get irritating.

Just read through the whole post, great build man!

Cheers man thanks!

[TeXJ]

Just read through the whole post, great build man!

[jeenyus]

great work! I feel like down the road you're going to wish you went with a LWFW. Especially with rev matching and low end engine speed. I'm probably projecting, but it's def one of those things I wish i had done while i could.

[Nick_S]

Still waiting on parts to show up. Decided I'd go clean up the engine a bit more and replace the thermostat and housing since it's been dribbling some coolant apparently. I also wanted to change the thermostat as I had lower temp one in instead of the correct one for the engine.


Had this for awhile and never got around to doing it. I believe it's an 88C one replacing an 80C I had in.





Drippy drippy



Torn down



That's better.




Planning on getting some cloth tape and cleaning up the engine wire loom a bit. Going to re-route some of the harness and secure some loose ends a bit better.



And then start cleaning the bay up. My order from Condor came in so tonight I'm going to try and tackle the steering coupler and get the new poly mount in there. Hope that fixes some of the slop in the steering. A new rack would be great but that'll likely wait till spring time when I plan to refresh the suspension.