Chapter 3 - 84 318i m-tech - M60 powered.

[Jean]

Let us know how the power steering works out. I want to add it back to mine, but I'm lost on where to start. I have the stock M60 540i pump and a E46 330i rack.

Sure, you need to get a custom high pressure line made by someone who does these or transmission lines . Should cost you under $100 total .

The other two lines are low pressure , use half the hard line from the m60 pump as it routes up the engine bay past the alternator and exhaust and from there run a soft line to res, and another line from res down to the rack .

[delamaize]

Let us know how the power steering works out. I want to add it back to mine, but I'm lost on where to start. I have the stock M60 540i pump and a E46 330i rack.

[Jean]

Got a couple more things done today -

- expansion tank mounted, I tried 3 different combination of tanks (e30 late model, e30 early model, and the e32/e34 tank that sits at the firewall) and picked the one I liked the most from aesthetics and serviceability.
- coolant hoses routed / test fitted
- fuel filter installed (used half of another external fuel pump bracket as a fuel filter holder)
- replaced some old fuel lines
- installed new throttle/gas pedal bushings (highly recommend doing this)
- test fitted hood to make sure clearance is good (ended up lowering the clutch/brake red about half an inch)
- tried both e36 lower radiator hose and e34 540i hose, went with 540i hose as it simply fits better after cutting about 1/2" from both ends and it doesn't rub against the oil dipstick tube (e36 325i hose does not have the needed curvature)









Need to get some heat reflective material/tubing to wrap the soft fuel lines in the engine bay and also power steering res lines.
Also will probably shorten the res lines and make a small holder/bracket to keep them close to firewall and away from back of the engine.

[Jean]

Can I get a picture??? This part will work for me i think with another extension piece.

The long straight gates hose is pretty expensive at local shops, so order it on eBay or Amazon it's almost half price there.

Here you go buddy! Tomorrow I'll get a new 540i lower hose and see how well I can get it to fit e30 chassis/z3m rad..as it fits much better than the e36 lower hose due it's perfect angle that goes around the m60 oil dipstick tube.

[dasmanschaft012]

Update:


- got another gates 18965 long straight hose with the molded end on one side that fits PERFECT on the 325e expansion tank, and the other end fits perfect as well on the 740i pump side for expansion tank...hose is long enough to use w/o any splicing. This is the hose I used (shortened) for one of my rear heat hoses, the molded side is perfect size for the rear water accumulator side and the other end is perfect size for the hard lines for the heater hose connections,.

Can I get a picture??? This part will work for me i think with another extension piece.

[Jean]

Update:

-got the power steering system/lines all finished up today.



The only thing I don't like about the power steering setup is it seems the return line from E30 res down to the pipe seems just a HAIR too lose to my liking, using a brand new hose and it fits the RES side perfect but the bottom isn't as tight.

Starting to wonder if there is a difference in PS res between e30 (what I am using) and e46 for example ...or perhaps there is not e46 rack banjo end fitting I can find with slightly BIGGER diameter to fit the hose perfect. The banjo end fitting on the lower pressure side would need to match the diameter of the plastic RES side.


-got oil filter housing lines/return line finished today
-oil filter housing oil bracket re-installed, learned that you can't order the center plastic support bracket that goes inside the 96+ housings, that's the screw-in part vs the plastic tower that snaps in in the earlier cars.
- removed spark plugs, put a little bit of oil in each cylinder, rotated the engine a few rotations to make sure nothing was binding and just wanted to get some lubrication in each cylinder
- torqued new plugs in place
- checked each ignition could with DMM , then re-installed in place
- traced the fuel return and charcoal canister lines
- test fitted smaller oil filter in the back of the car near the external fuel pump
- got the e36 lower radiator hose, don't like how it fits , it rubs against the oil dipstick tube too much, this is the GATES 22440 hose. This hose can actually be used for the UPPER radiator hose though.
- got the gates 20923 for the upper radiator hose, shortened it and it fits perfect as the UPPER radiator hose.
- got another gates 18965 long straight hose with the molded end on one side that fits PERFECT on the 325e expansion tank, and the other end fits perfect as well on the 740i pump side for expansion tank...hose is long enough to use w/o any splicing. This is the hose I used (shortened) for one of my rear heat hoses, the molded side is perfect size for the rear water accumulator side and the other end is perfect size for the hard lines for the heater hose connections,.

- test fitted stock 540i/740i lower radiator hose 11 53 1 741 407 and it clears the oil dipstick tube obviously much better than the e36 hose. I may try to use this hose instead.

- tried re-installing new 540i throttle cable and for some reason no matter what position I try on the firewall side I can't get the throttle body to close fully even when the adjuster own the cable is maxed out. I may end up modifying the throttle cable metal bracket instead. Not sure why I am running into this issue, using the cable everyone recommends, bracket appears to be stock 540i and isn't bent or damaged ...cable is new, gas pedal linkage has been shortened to clear the wilwood pedals .

- got two DME's ready for the swap, both are manual 404 black label non EWS versions.
One with manual stock 530i m60 chip with b40 maps from DUMD, and second one is a virgin 404 black 540i/6speed manual chip as backup.
Got a stock 404 auto as well, just in case so I can compare these run and read (code wise).

- my old 15x8 tire rack e30 specific wheels reinstalled with new Kumho V720 225/45 tires (wish I waited and new about the new 15x9 and 245 options out now :./

- Starting to trace wires for the harness.

TO DO list is finally getting smaller :)

- figure out the throttle cable situation
- install new throttle linkage bushings

- run new wires for the check engine light and speed sensor
- run extra wires for future to add additional sensors (oil temp, oil pressure, etc)
- run battery cable to the trunk and install battery box
- re-install dash / interior

- get the lower radiator hose option figured out
- get expansion tank mounted and hose connected

- install starter
- get manifolds modified and installed
- get the stock b40 y-pipes modified and installed
- get walker cats installed order correct o2 sensors to match the wiring harness

[Jean]

Haha thanks man ! I know this swap isn't new, and crap I was supposed to have this one done 3 years ago but life got in the way and I had to pause it .

So yeah , lots of folks since then have completed this swap but there were certain areas that I thought I could improve on for serviceability and in some areas for aesthetics.

The car in question didn't come with abs from the factory and I never felt there was a reason to retrofit one , I've driven it through rain and California winter with both m10 and m30 engines and never had an issue as long as tires were good and you pay attention.

Now, ac was removed many ages ago and sometimes I wish I kept the hard lines in the engine ...I may add ac back in the car but what I have in mind will be also different from what people have done with this swap . The passenger side frame rail clearance does not allow for compressor to fit without cutting into the frame rail a couple of inches , that's something I am not willing to do . My plan is to utilize the stock mounting points for the passenger side bracket / engine arm and get a custom bracket fabricated to bring the compressor closer to the engine and also utilize a smallest compressor I can find to fit in there . Who knows maybe this won't even work, but that's an idea that I'll follow and see how successful it will be.

And looks like I've found out more about the oil filter housing support bracket , there was a service action by bmw to update the support bracket in order to allow for "more environmentally friendly oil filters "

I haven't seen anyone report this issue here yet , perhaps no one has tried replacing that part with a new part and then discover this issue :/

[flyboyx]

holy crap jean! this is one of the best and most concise engine swap threads i have seen here. good on you for posting your trials and tribulations. this will be so helpful to those that follow you in the future.

why no abs? i see you have an early 318 car. i assume it did not come installed from the factory? i am really happy to see the filter housing bracket worked for you.

do you plan to run air conditioning?

also....sub'd

[Jean]

Update - used http://www.autohausaz.com/pn/32411095526 as it fits perfect from the res to m60 hardline going to the power steering pump. Trim it to fit .

For the steering rack to res I found 1/2" transmission/power steering hose sold by the foot and used that.

Of course it wouldn't be my typical day if I didn't run into some issue. I ordered a replacement m6x 740i oil filter housing filter support element, and it doesn't fit. The one in my oil filter housing is threaded on the bottom, and it seems the only ones I can find to order are SNAP-IN with o-ring on the bottom ?!

Part #22 - http://www.realoem.com/bmw/enUS/show...diagId=11_1414

http://www.autohausaz.com/pn/11421745392

Sigh. Looks like I am not the only one who ran into this - http://www.m5board.com/vbulletin/e39...r-problem.html still trying to figure out solution....

[dasmanschaft012]

http://www.pelicanparts.com/catalog/..._pg2.htm#item6

[Jean]

Anyone know who would carry low pressure power steering hoses in bmw sizes, just tried CarQuest, O'Reilly, Napa, AutoZone and only found 1/2"

[sonomabimmers]

subd

[Jean]

I am cutting off the round 20 pin C101 and turning the chassis side to 25pin C101. It was originally square plug c101 that I've cut off and turned into round 20 pin when I did my M30 swap. I don't see any reason to make an adapter, since I have to run some wires such as check engine, speed sensor separate as they aren't even part of the chassis harness on my car. Just want it to look clean and factory looking.

It looks like the DME end might just reach into the glovebox area...otherwise I'll probably just have to extend all 60+ DME wires or build some kind of box to sit where the battery was like it does on e32/e34 cars and add cooling for it.

- TO DO LIST -
Finish power steering lines (res to pump, rack to pump)
Connect fuel lines from rail to the hard lines on firewall (need a good photo showing what line is RETURN and what line is for CHARCOAL can)
Install fuel filter near rear subframe area near external fuel pump
Add some oil into cylinders for lubrication
Fit the oil filter lines
Fit the oil filter to pan return line
Fit the alternator power wire
Modify throttle cable holder bracket
Run wires for brake light switch
Run wires for reverse light switch
Get upper and lower rad hoses, and expansion tank hose
Finish manifolds/downpipes/exhaust
Get cats and exhaust piping
Get o2 sensors
Fit expansion tank
Finish wiring
Reinstall dash/interior

[dasmanschaft012]

Are you cutting off the C101 body harness plug and just extending the wires to the new plug? or are you making a plug in adapter?

[Jean]

Made some more progress today, got lower brackets made and installed for the radiator. Since I have an early 318, the previous rad mounts didn't fit the Z3M rad on the sides so had to get those made.

Found a spot for the 540i charcoal canister behind the driver side headlight and ran a new line through the frame rail for it. Removed the oil filter housing to install new upper/lower o-rings and test fitting the low pressure power steering hard line for the res.



Had a local hydraulic shop make me a new high pressure line, test fitted it. It has an "S" bend to it, so it's not really as straight as it looks in the photo.



I really like the radiator to engine clearance, test fitted stock intake manifold that also will need some custom bracket / mounts fabrication for install.

Got a 540i throttle cable installed, and hooked up to the gas pedal and ran into an issue. With the pedal in fully closed (up) position the throttle body isn't fully closed.... As much as I'd like to drive all the time at WOT this won't work. It looks like one way I can get this resolved is by modifying the metal bracket that holds the end of the throttle cable on the throttle body. I'll need to move the point where the end of the cable/rubber bushing is about 1/2" closer to the front .





I bought an early style expansion tank to see if the fitment of it would be better than the late model, test fitting it and looks like I'll go with this one instead of late model version. I didn't want to add more things to the driver side fender area and have the expansion tank instead live on the passenger side and hose will run to the 3rd nipple on the 740i pump.

I am not a big fan of it covering half of the valve cover, but I still think it's better than running it on the driver side and having yet another coolant hose added to the area that's already pretty busy near the firewall.