I'ts Alive

[DailyE36]

so i have been busy lately.
parts list..
Piston Pin Snap Ring
Crankshaft Main Cap Bolt
Cylinder Head Bolt Set
Head Gasket Set
Oil Pressure Relief Valve
Oil Pump Rotor Set
Spacer Bushing
Main Bearing Set
Rod Bearing Set
Connecting Rod Bolt
Genuine BMW Piston Rings
Timing Chain
Timing Chain Rail
Timing Chain Rail Lower
Timing Chain Rail Upper Slide Rail
Chain Tensioner Rail
Timing Chain Rail "Deflection Plate
Spring
Water Pump
O-Ring for Water Pipe
Water Pipe Connector
Engine Mount
Knock Sensor
Camshaft Position Sensor
Crankshaft Position Sensor
Transmission Mount
Output Shaft Seal
Input Shaft Seal
Selector Rod Seal
Tension Bushing for Shift Rod Coupling
Shifter Arm Plastic Bushing
Rubber Buffer
Shift Tower Bushing for Shift Lever Pivot
Shift Rod Joint
Bushing for Shift Lever Support Arm
Shift Rod Circlip at Shift Rod Joint and Shift Lever
Flex Disc
Center Support with Bearing Assembly
O ring for Heater Core Pipes
Heater Core
O Ring for Heater Valve
Heater Pipe
Heater Valve
Activated Charcoal Filter
Heater Hose, Outlet to Return Pipe
Heater Hose From Heater Valve
Heater Hose Return
Heater Hose, Inlet from Back of Head
VW lifters
cams
flywheel bolts
clutch cover bolts
exedy clutch kit
m40 flywheel
blower motor
ect

reshaped the rear of the throttle and knifed egged the butterflies


did the same for the lower intake manifold. also polished the intake runners and port match


clutch and flywheel i got months ago.














exhaust manifold had over 3 cracks in it.



















my work space. long hours spent here






the engine had over 300k on it and the bearings still looked ok.






removing cams ect.




yep this is how clean the head looked

[DailyE36]

tapped up the exhaust ports for polishing


same thing here for cleaning the head


i removed the pilot bearing using a bolt with a nut on the end to catch the inside of the bearing while hitting the hammer (arrow) with another hammer, using cardboard to protect the sealing surface just in case.




bolt and nut


when things get serious






cam treys ready to be cleaned


some damage on the rear bearing surface on both cam trays


parts from pelican


new style plastic oil pressure relief valve (old style tends to get stuck resulting in oil pressure loss)


the correct spring and spacer is also needed for this to work properly


new main bearing set with 360 thrust bearing (stock only has 180)


steel water pump


micro filter


and its surface area


new oil pump


some new bling


gasket sets


installing new heater core




new filter and blower motor installed


draining gearbox befor fitting new seals


VW lifter vs stock m42

[DailyE36]

no mods needed for them to fit




measuring to make sure everything is ok before assembly




only thing is the length is different, but still works fine.




head cleaned






left the intake ports stock








polished as much as i could be bothered, 99,9% polished.




cleaned the valves as much as possible




old vs new oil pressure valve






new oil pump installed


hone the cylinder walls using a flex hone with 240 grit.




painted the block non-gloss gold, cos i can

[DailyE36]

lubing the bearings ready for assembly


gear puller to remove the gearbox rear flange


30mm deep socket with wall grinded down so it will fit.




shoved a bolt in the flange while removing the nut


sorting out the sump




WTF is this ?





256/256 10.5mm lift. for the street.




first piston installed


and the rest










i used tape to hold the vw lifters in while placing the trays in the head.


looking sexy


lubing




schrick vs stock


schrick cams with light vw lifters




the gangsta chain is on

[DailyE36]

flywheel on


clutch on


going in the car






replacing the center bearing


bracket made up for the A/C fan with no A/C








done, a little dirty, but done



primed the oil pump by filling the oil filter housing with oil and put the filter in and crank the engine over with no spark plugs in and no fuel for 30sec bursts. oil pressure light went out after second burst.
so far running good and smooth but have a coolant leak at the fire wall. will fix tomorrow.
thinking about dyno tune when the engine is run in. not sure what power the engine will do but anything more that stock is a achievement
any questions about part NO. or anything feel free to ask.

[illiano]

Beautiful work.

Is that a 928 I spy?

[flyfishvt]

EPIC!!!!


How much was shipping on all that?

[DailyE36]

Beautiful work.

Is that a 928 I spy?

its a 944 turbo.

EPIC!!!!


How much was shipping on all that?

most of these parts came from the US and cost hundreds in shipping.

[BimmerJM325is]

woah.. wish I could have watched all that in person as it went down. Would have learned a lot! Nice work!

[cabdolla]

hey fantastic work man.

[fahdyehia628]

TOTAL RESPECT !!!!

That's alot of work and time and money spent on that engine

Congratulations

How does it feel before and after ?

[NJohc]

... That's exactly what Ive always had in mind for mine. How long did it all take you?

[DailyE36]

i have only driving once so far and feels smooth, the revs come up noticeably quicker, cant thrash it yet so not sure on the butt dyno. the clutch grabs really fast so have to get used to that.

total time from start to finish including waiting for parts multiple times was around the 2 month range. total engine build time one week everyday befor work.

[DailyE36]

when to the dyno today to get a quote on a run and remap. they said that they will run the car on the dyno and check if everything is ok and they will tune it if needed for $190, but. the DME remap was quoted over $1K? that's pretty steep. so ill leave the remap for another time.
as of now the car has over 700km on it. when i hit 1000km ill do a service and the drive to the dyno.
i'll post up results when it's done. without a remap it will be average

[flyfishvt]

Read over this thread again and I have a question on the cam bearings. I see you used a ton of lube on them. Doesn't all that lube cause a large buildup so the caps wont torque down correctly?

Hope you can understand what I'm getting at.

[DailyE36]

if the engine blows up ill just throw it in the bin and buy something better

[flyfishvt]

I was actually looking for a more technical answer. Im not questioning your incredible work. Just curious

[Moron95M3]

I was actually looking for a more technical answer. Im not questioning your incredible work. Just curious

what torque are those seeing? I'd assume there'd be plenty of force on the bushings to squeeze out any lube that shouldn't be there.

I was thinking the same thing when I saw it though.


Nice work Daily!

[slocar]

what torque are those seeing? I'd assume there'd be plenty of force on the bushings to squeeze out any lube that shouldn't be there.

I was thinking the same thing when I saw it though.


Nice work Daily!

I think for M5X motors it's something like 20 pounds then another 50 degrees; this should be similar. Either way, I agree ... it's lube, it will sqeeze out.

OP, gorgeous m42. Now all you need is a supercharger strapped to it.

[DailyE36]

after i took the pic i smoothed out the lube with my finger (i didnt want lube on my camera) i can't remember if lube got between the joining surfaces but so far i have had no problems.
and in the future when i get bored i might supercharge the car. but i doubt that.
going to check out another dyno place today for prices.

[28Chillin]

Awesome post. Must have taken a long time to set up the pictures. Thank you.
Undercover Stealth Kitty caught on film-

[clumsyculhane]

That is incredible, haven't seen many people put that much effort into a 4cyl. Looks amazingly clean, should be right for another 200,000 km's now :P Are you in Victoria? If so, where did you get your head and stuff cleaned?

[motion]

Great job! Consider investing in a set of fender covers to protect the finish of a very nice car.

[DailyE36]

That is incredible, haven't seen many people put that much effort into a 4cyl. Looks amazingly clean, should be right for another 200,000 km's now :P Are you in Victoria? If so, where did you get your head and stuff cleaned?

i live in south australia. i got the head cleaned in adelaide 3 years ago when the head cracked. this time i just cleaned it myself.

getting dyno tune next week. engine has 1000km now and gave it a thrash. feels a little faster, the revs are a lot smoother especially in the hi-rpm range. spins the wheels shifting from 1st to second, more than it did befor..

[DailyE36]

so the car made 90kw at the wheels today, it was running lean in the hi-rpm range so the guy tuned the AFM. the ecu is still running off stock maps. a ecu remap will be the next thing, but not for a while.
the dyno guy said that the car is throwing down 180hp at the engine! if thats true than