E36 3.0 ITB Race Build

[Addicted]

Re: E36 Track Day Hack (v2)

wish i knew how to do this stuff.

great build

Couldn't of said it any better myself. Hoping to get an mx-5 or something in the Summer to start learning!

Fantastic write up as per Jord, real interesting stuff for a newb like me!

 

[Jon.G]

Re: E36 Track Day Hack (v2)

Glad this is now working out for you and decent progress this weekend. I've got an M54 sat in a shell if the 50/52 doesn't work out.

 

[Gray]

Re: E36 Track Day Hack (v2)

Nice work, Jord. Glad this one has gone together ok!

 

[f0xy]

Re: E36 Track Day Hack (v2)

Good progress Jord. See you're building a collection of Bimmer bits as big as you did with Clio bits. Lol. Many trackdays planned for next few months?

Its worse than the Clio days, I've got an entire engines worth of spares lying about from the M50, and a couple of blocks. One other cast iron block that is good which I'l keep. Entire rear original rear subframe assembly, and tons more. Luckily its not kept at home or it would all be in the bin!

Nothing planned really. Probably do one in May sometime, want to get it out soon-ish if the new engine is all good once it goes in.

Glad this is now working out for you and decent progress this weekend. I've got an M54 sat in a shell if the 50/52 doesn't work out.

Quite common to do the M54 crank/rods/pistons into an M52/50 to get a 'cheap' 3.0L, and a lot better torque delivery due to the longer stroke, but its the messing about with mapping a standard ECU to suit etc which I can't be bothered with. If I already had aftermarket management it would be a perfect change to make, but I've stuck with the 2.8L to keep it simple with the map I've already got etc.


Finished it off today, started with fitting the new crank seal to the flywheel end..

Then the crank seal on the timing end, along with the crank pulley and a new crank bolt. Torqued up to 450NM.

Fitted a new metal impeller waterpump and seal..

Then the crank pulley/timing ring itself, waterpump pulley and metal thermostat housing with new seals and a new 88C thermostat..

Fitted a couple of other bits, knock sensors, coolant temperature sensor and coolant return to the head..

Lastly the rocker cover went on with a new gasket and torqued it down..

...and there it is. One new M52/M50 hybrid engine ready to drop in. A few bits will be swapped from the current engine when its removed - oil filter housing/oil cooler, single mass flywheel and clutch, inlet manifold, exhaust manifolds etc.

The plan is to do the swap next weekend, but Im thinking of pulling some un-required bits from the engine bay and painting it between, so it might stay out for a week. Will have to see later this week.

 

[DanielJames]

Re: E36 Track Day Hack (v2)

Good work mate.

Once again thanks for the help on Friday. Shame the E36 wasn't there would have loved to stick around and learn as you did this...

 

[Chi]

Re: E36 Track Day Hack (v2)

Bloody brilliant mate. .. Oulton May 27th?

 

[f0xy]

Re: E36 Track Day Hack (v2)

Bloody brilliant mate. .. Oulton May 27th?

Possibly, there isn't much else on in May, well on the right day anyway. I'll see how I get on with the new engine and running it in, then go from there. All being well it should be fine..


Had a free afternoon today so removed everything leaving just the engine ready to lift out..

Hopefully get to do the actual swap at the weekend

 

[Chi]

Re: E36 Track Day Hack (v2)

If you need someone to make brews I'd love to get involved. ..

 

[f0xy]

Re: E36 Track Day Hack (v2)

If you need someone to make brews I'd love to get involved. ..

Don't drink tea but anything else then yeah, lol!


So during the week I did a few bits. Put some new spark plugs in, coilpacks on, cleaned and painted oil filter housing, new oil filter, some of the ancillaries on, etc. Saturday I got the old engine ready to lift out - removed exhaust, propshaft, wiring, inlet manifold, etc as mentioned above. Couple of hours later..

Removed the gearbox from the old engine, then the clutch and flywheel.

Fitted the solid water pipe to the block, then the oil setup/vanos feed/oil pressure sender much tidier than last time..

Engine bay was gunk'd and jetwashed, came up OK. Gave the visible parts some fresh paint too.

Flywheel and clutch then onto the new engine..

Then fitted the M3 (ZF 5FD 310Z) gearbox, which I had previously cleaned and painted. Also fitted a new pivot bushing and retainer to this..

Lastly fitted the M3 manifolds with new nuts (as it was such a PITA to fit these with the engine in the car!)..

Finally..

It was no easier putting the damn thing in with the manifolds fitted, took a long while. Just as hard as fitting the manifolds once in place, but got there in the end. By this time it was dark and enough had been done for the day!

 

[tomhunt85]

Re: E36 Track Day Hack (v2)

Progress is looking good.

 

[f0xy]

Re: E36 Track Day Hack (v2)

Started by getting the gearbox and engine mounts fully bolted up today, then connected the prop shaft, exhaust and a few other bits under the car. Had to replace the clutch slave cylinder after the old one fell apart when removing it from the old gearbox. Fitted this also.

Tidied up the loom, connected and routed all the connections up properly. Connected the remaining coolant hoses with new clips. Cleaned the PAS reservoir and hoses.

Next up was the inlet manifold, crankcase breather, injectors, fuel lines, etc. Connected the oil cooler/lines and various other connectors..

Gone to a 19 row cooler, up from 16 row. Also going to be mounted sideways, with the inlet at the bottom, so it can't drain empty when the engine is off (giving incorrect dipstick reading)..

Loosely assembled the front end to get the radiator and upper hoses in place. Changed one of the oil line fittings to a straight instead of a 90 degree, then got in approximate position (mounts are yet to be done).

Filled the engine with oil (mineral for running in), coolant system with water (for now) and lastly some PAS fluid. Disconnected ECU and cranked the engine over for a while to build some oil pressure. Checked the oil again and all OK. Then..



:clap:

Ran it for a couple of minutes and no leaks, oil or water. Very smooth and all seems well. Very good oil pressure too. Just need to bleed the clutch, reassemble the front end and adjust the gear lever (M3 gearbox must be in a slightly different position). Then the running in can start!

 

[welshname]

Re: E36 Track Day Hack (v2)

Great progress. Nice to see it all coming together after all the set backs you've had. Look forward to seeing it at Oulton on the 27th.

Did notice something sounds a little whiney on idle though, assume it's just PAS pump or Alternator?

 

[f0xy]

Re: E36 Track Day Hack (v2)

Yeah, could be the aux tensioner too. I've not fitted the newer one yet, or the new auxiliary belt. Just wanted to run it and check for any leaks/issues first etc. Was pretty quiet after about 10 minutes, needs driving to properly fill the hydraulic lifters too though, and need to put some load on it/run it in rather than just run it on the drive!

 

[welshname]

Re: E36 Track Day Hack (v2)

Excellent. Fingers crossed there are no more surprises!

 

[f0xy]

Re: E36 Track Day Hack (v2)

Hopefully yeah. The M3 box is an unknown, will have to see how it goes once its driven. Worst case I've still got the 200k+ 328i (basically the same box) if there are any major problems. Want to get a good 500mile+ on it and then drain the mineral oil, should have a good idea of how well it is then.

 

[Chi]

Re: E36 Track Day Hack (v2)

A mate of mine is breaking a 328, I'm sure you have everything and spares but thought id mention it..

 

[f0xy]

Re: E36 Track Day Hack (v2)

I have a stupid amount of spares, but... I am after a few bits. Can you find out what colour it is and what colour interior its got?

 

[Chi]

Re: E36 Track Day Hack (v2)

The car is green mate and i got 1.red and 1 cream interior for a coupe
was his reply

Said he has a spare engine and box too mate.

 

[f0xy]

Re: E36 Track Day Hack (v2)

Got too many engine bits! I'm after the heater control valve from the bulkhead (engine bay side) as mine has a broken connector and a grey glovebox if he has a dash that was that colour..

 

[f0xy]

Re: E36 Track Day Hack (v2)

Had a couple of hours spare earlier, finished the oil cooler mounts. With it now being on its side, instead of upside down, I had to start again. The top was easy, some 90 degree 6mm plate and a few holes. The lower two from 3mm bar bent to shape. I wanted to put something soft between the mounts/cooler, so originally spent ages searching for rubber washers. Eventually realised an internal tap washer is the same sort of thing, and works perfectly for the M6 bolts.

The pipes are routed slightly differently, swapped one of the 90 degree fittings for a straight fitting (top) also. Protected the braided hose with some heater hose wrapped around.

Finished by bolting all the front panel up properly.

 

[Chi]

Re: E36 Track Day Hack (v2)

Can't wait to see this in action.

 

[DTM Cars Ltd]

Re: E36 Track Day Hack (v2)

Good work foxy lad. Will be like the old days at in the 16vs

 

[f0xy]

Re: E36 Track Day Hack (v2)

Good work foxy lad. Will be like the old days at in the 16vs

While ago that now, finally rid of all my Renault stuff!


Moves under its own power now. Spent some time modifying the position of the gearstick earlier, then clutch bled with the new slave cylinder and fresh oil in the gearbox. All gears engage fine and the clutch position same as before. Not much else to do now before it can be run in.

 

[f0xy]

Re: E36 Track Day Hack (v2)

So over the past few days, I took some time making sure all the brackets/wiring was tidy/etc. All the front-end went back on, also drilled the bumper and cut out a slot in the aluminium slam panel for more air-flow on track..

One of the last jobs was to re-fit the bonnet catches, which I spent ages messing around with and couldn't get it to latch correctly, and the lever (for releasing the bonnet once popped) kept catching on the top fitting for the oil cooler. I had given up with it by then and decided to remove the standard mechanism and fit the pair of aero catches I had from previous cars.

Carefully marked up the bonnet and slam panel to make sure the position was right, then drilled everything. Cut the bonnet and got the holes right for the catches and got those fitted. Then realised, where the pins were on the slam panel was slightly too high to get the top nut on to secure it. Had to get a bit creative and mount them slightly lower on a new bracket, without getting in the way of the headlight..

After a lot of fiddling, finally got there, and all works well. In the meantime I had to go to the scrapper for an indicator connector, as my original one had broken off. Spotted a 525i there, looked a bit closer, and saw it still had the M50 fuel rail on it. Had that and will swap it on in the future, straight bolt on without the need for adaptors on the mounting points..

So once the indicator was sorted, everything was ready to go..

Checked the fluids and took it out to start the running in - everything works awesome!

The engine is tight as expected, but very smooth and quiet. Only took it up to circa 4k and keeping it loaded at the moment. Approx 50 miles in and can feel it opening up a bit, that was it for today. The M3 gearbox has a bit of chatter on idle once warm (input shaft due to the single mass flywheel conversion). Oil pressure is very good (better than the old engine), temperatures are solid and the oil cooler is working fine. No leaks anywhere either. Overall very happy with it! :clap:

Going to continue the running in over the coming days, along with a few other bits and pieces. Hopefully all will remain fine!

After finding out two of the four 'track' wheels were bent, and finding two straight replacements, I decided to get my uncle to powder coat them, as per all the subframe stuff. Decided to go with a different colour instead of the usual silver/anthracite, not tried them on the car yet but il leave this here for now..

 

[JackJack]

Re: E36 Track Day Hack (v2)

Wheels look cool.

 

[dmallett]

Re: E36 Track Day Hack (v2)

I love your projects!

wheels look nice too

 

[f0xy]

Re: E36 Track Day Hack (v2)

So after loosing the pressed in rear studs on the N/S when the stub axle was scrapped, I decided to be done with it and try to source some cold rolled bullet nose studs at a reasonable price (ie. Not the prices Pure Motorsport and various other vendors are charging!). Easily found in the US, in any length, but after shipping and taxes it soon adds up.

Eventually I found some 90mm's in the specification I wanted, imported from the US, at a great price. This morning I set about fitting them to the three corners that didn't have studs, as the O/S rear still has the pressed ones for now.

Threads cleaned of all dirt and grease..

Studs wound in with stud lock and torqued to 25lb/ft..

Fitted everything back on. Still got plenty of stud out the end of the nut even with the 15mm spacers on..

Fitted the 'track wheels' to see how they look, then back out to get some more miles on the engine and took a few snaps..

No issues have appeared as of yet!

 

[Russ_16v]

Re: E36 Track Day Hack (v2)

looking good mate!

 

[welshname]

Re: E36 Track Day Hack (v2)

Looks really purposeful with that stance. Good work.

 

[Joe#]

Re: E36 Track Day Hack (v2)

Coming along brilliantly Jord.

 

[Chi]

Re: E36 Track Day Hack (v2)

Brilliant can't wait to chase this round Oulton

 

[DaveDreads]

Re: E36 Track Day Hack (v2)

That looks mean!

 

[JoeyD]

Re: E36 Track Day Hack (v2)

Yeah, that looks great! Absolutely awesome work

 

[f0xy]

Re: E36 Track Day Hack (v2)

Cheers for the comments everyone. Can't wait to really open it up properly after I've done these miles to run it in, should be much better than before. Handful of little bits to sort before Oulton but nothing major pending the engine continues to be fine!

 

[f0xy]

Re: E36 Track Day Hack (v2)

Passed 250 miles now, top end (3.5k>) is just awesome. Induction noise is much different (probably due to slightly different CR) and it pulls like a train. Had it up to 7k a few times. Couple more hundred and it should be all good.

 

[Christopher]

Re: E36 Track Day Hack (v2)

Amazing. Just read the whole thing over the last week or so... love the job you've done.

I'll probably be at Oulton too so I'll see you then.

 

[f0xy]

Re: E36 Track Day Hack (v2)

Cool, yeah should be a good day. Its been a while!

 

[f0xy]

Re: E36 Track Day Hack (v2)

So after the scrap yard fuel rail find last weekend, I wanted to fit it with new lines (they are on opposite ends of the rail on the M50, rather than both at the same end like an M52). Picked up some fuel hose clips, and some new 8mm fuel hose. Removed the old rail, and injectors. Cleaned, painted and fitted the injectors to the M50 rail..

Then fitted it to the car with the injector loom and new fuel lines..

This eliminates the need for adaptor brackets to make the M52 fuel rail bolt upto the M50 manifold. I didn't NEED it, but while it was there at the scrapper its tidier and now has new fuel lines too.

Browsing some forums I spotted someone selling some ABS formed ducts that looked about the right size to get rid of the manky fog lights on my front bumper. After a quick measure I got them cheap, and they arrived earlier in the week. I ripped out the standard fog lights and brackets, leaving two empty holes in the bumper. Used some cardboard to make a template of the shape, and got to work with the grinder/file..

I made sure they were a tight fit, then bonded them in place on the flat parts where the fog light unit bolted to, and all the way round the back..

Turned out quite well, and looks much better than empty holes or old fog lights. Although, I've not done this for looks, as they are being used for brakes, which I'm in the middle of doing and will update in due course. More soon!

 

[f0xy]

Re: E36 Track Day Hack (v2)

Spare set of calipers were powdercoated at the same time as the other orange bits a while ago, but I've only just got round to building them up. Cleaned out the bore first, then cleaned up the piston..

New seals fitted, then put into place, sliders fitted to carrier and put together. New bleed nipples also.

Then a new pair of these to go with them..

Stuck with the Carbone Lorraine RC5+ also..

Both sides on, bled up, all good. I also built up the powder coated rear calipers, using the same new seals, etc, but it turns out they are not from a 328 and no good for me as they don't fit! So if anyone wants some brand new 325i E36 rear calipers in orange let me know!

One of the centre exhaust rubbers had also broken, so a few quid later on eBay got me these, which were then fitted..

Lastly was to replace the 5k old air filter. Never seen one so bad in such a short time!

 

[Jamie86]

Re: E36 Track Day Hack (v2)

Didn't fancy a caliper upgrade then?

Or is there not one at a decent price?

P.s is the old oil cooler for sale?