'89 318i 6 speed m50b32tu turbo swap build

[ba114]

where did you get the head modded to suite Dual Vanos? i want to run a m52b28 in my e46 touring

Modded at home with carbide burr

[ba114]

Taking up the challenge from facebook, it's time to make a proper update to this.
Progress is very slow, with another child just arriving in January i haven't had any real time to dedicate to the car to get it built. I had planned to have it ready to drop in over easter, but that might be a bit far-fetched now.

So to start with, finally pulled the old motor to identify where it failed, and as suspected, it was ringlands. Note: 20+ psi on stock ring gaps is a no-go.


Twin disk 1040nm setup for gs6-53bz arrived from adamat. This was a custom job that uses the m5x ring gear to allow using an m5x starter instead of the n54 starter.

[ba114]

When it came to mounting the windage tray, i could not get it bolted down. The arp main studs protrude higher than stock bolts so this required notching the windage tray.


Fitted an oil pump chain tensioner. This will complement the new crank sprocket and custom 7 bolt m54 oil pump modified to work on m50/m52 motors - this was a custom job from finland. Before removing the e34 pump and pickup, i made a jig to mark where the oil pickup was so i could get the new setup in the same location. I used a 728i front oil pickup which needed to be shortened slightly and re-welded.


Modified an m54 thermostat to work with m50 head. basically involves removing the spring from under the bypass plate and creating a spacer to hold the bypass plate down under the circlip. This gets the bypass plate to the same position as a stock m52 thermostat. Without doing this, the bypass port would be constantly blocked. Taking the gasket out of the m54 thermostat and placing on the m50 head seems to indicate it will seal.



Difference in gearbox length between gs6-37dz and gs6-53bz. The e36 325i driveshaft will compress enough to make up for the difference. I had the front half of a 135i driveshaft (106mm guibo) grafted onto the stock e36 325i driveshaft. After the fact i learned that the output flange from an 420g gearbox will apparently bolt up to a gs6-53bz which would have negated needing a custom driveshaft.


Cams in and timed. Dual Vanos unit mounted and m56 valve cover painted in zinnoberrot to match the body paint.


Designed and 3D printed (CF nylon) a spacer to allow the use of the MS43 crank sensor on the front timing cover as the m50 block has no provisions for the rear mounted crank sensor. Made an extension harness as the stock wiring cant reach to the front timing cover. Anyone else that needs to do this, the connectors needed are Kostal 09442311 (22140492050).

[Northern]

Flywheel/Clutch setup looks great!

[ba114]

Drilled and tapped m50 oil filter housing to fit ms43 oil temp sensor

[ba114]

She's in!

[ba114]

Fitted up the e90 booster and master. Used a T-piece for splitting the front brakes and the grabbed a brake line from an e60 that has the correct m12x1 fitting on one end of the line and m10x1 on the other end. It's 190mm long and the perfect length for what I wanted to do. I also got a reservoir for the e60 as well which fits up and allows you to put the push rod through the master and reservoir to secure it.

[ba114]

Needed to tidy up the shock towers. Years of abuse saw lots of damaged paint so was time to give it a fresh coat....yes I should have done this before putting the new engine in... Anyway, it's done now, looks OK. Fitted the turbo to wrap up for the night. Sent from my SM-G973F using Tapatalk

[ba114]

Been tinkering with the 3D printer in the evenings and modelled a centre air vent to make a housing for a palm phone. It will also house a wireless charger to keep the phone charged. The phone will be connected to my jb4 for gauges, logging and map switching. Sent from my SM-G973F using Tapatalk

[Northern]

Looks good, keep it up!

[ba114]

Been thinking about brakes more and more lately as i now have the 25/22 e90 master instead of the 22.2/17.46mm stock master, and decided its time to invest in a bbk.
I've been looking at the IE 310mm wilwood bbk kit. Seems like a good package that will fit my 16" esm002r.

Unfortunately there are two issues:

1. The calipers supplied are the 120-13434 and 120-13434 which has the 1.62, 1.12, 1.12 pistons in it; 4.04" piston area when paired with the 310mm front rotor, and running stock rear brakes setup, the front bias would be a huge 78% which is not acceptable. To fix this needs more fixes:
   • Replace the calipers with 120-13438 and 120-13439 which have 1.38, 1.0, 1.0 pistons; 3.08" piston areas.
   • Replace rear brakes with 36mm bore Z3 calipers which are direct bolt on to e30.
   • Re-drill 10mm e36 325i 280mm rotors to 4x100mm and have a ring machined to centre on the hub, or i engage a rotor manufacture for a custom spec item (im exploring this further right now).
   • These changes combined will bring the bias back to 67/33
2. Shipping from USA to Australia is ridiculously expensive. IE will sell me the kit minus rotors to try save on shipping costs...but we'll see what the quote comes in at.

The other issue i'm not clear on, is my stock master DEFINITELY is stamped 22/17. All my research suggests that the original F/R bias is around 63/37 yet my calculations are returning 57.5/42.5:

https://www.tceperformanceproducts.com/dual-bias-calc/

Can anyone explain why this is and should i be concerned by the fairly significant difference? If so, i can switch to a e46 325i caliper which would make it 62/38.

[Northern]

Have you factored in the pressure drop in the rear lines from the bias valve?

Some info here but a bit muddy to sort through

http://spece30.com/t/brake-bias/7736

I am going to do this at some point soon and I think I would try to spec everything to eliminate the stock bias valve, or use an aftermarket one if necessary to hit whatever bias range.

[ba114]

Got a new mig and decided it was to put it to good use. Fabricated a new gearbox crossmember for the gs6-53bz. Still running the e28 mounts with aluminium cups. Also made a tool for locking the crank so I could tighten the crank bolt. It looks ugly, but theres good penetration and the splatter is actually clear coat I sprayed while still hot.

[ba114]

Water feed for turbo


Hardline for turbo oil return


Radiator mounted, pipework attached

[ba114]

Fitted a HVAC panel from a LHD e30 so the radio would be moved to the left side. It needed a few mods, doesn't fit perfectly, but pretty close.


This was done to provide more visibility, and enable the fold out screen to NOT hit the indicator stalk. Why do i want more visibility? for the JB4 mobile app of course


Those of you with a keen eye will notice the 2nd image has a different headunit. I had to return the first one because of a horrendously loud white noise issue that was persistent unless you muted the sound.