It Begins....the E34 535iT project (56k warning)

[Mr Project]

Hi, I'm Mr. Project, and some of you might remember me from such internet forums as this one, a couple years ago. :) I used to have a '91 535i, but I sold it a year or so ago to a local friend.

It used to look like this:
http://img226.imageshack.us/img226/2277/img0788large4yh.jpg

A few months later, he decided he really needed a minivan (boo) so he sold it to another friend. About a month ago, on a quiet Saturday morning, I got a phone call from that second friend....he had just been rear-ended by a drunk driver.

http://img20.imageshack.us/img20/421/img2036large8on.jpg

I instantly knew this was the opportunity I have been waiting for and trying to arrange for years....I also happened to know of a 525iT locally with a blown tranny, owned by a mechanic friend of mine. Well, yesterday I managed to talk him out of the car for a reasonable sum. It's been sitting for 5 years in the back of his lot, so it is FILTHY. The paint is also in pretty sad shape. This is after a solid 30 minutes with my 2500 psi power washer:

http://img49.imageshack.us/img49/7258/img2031large3fc.jpg
http://img151.imageshack.us/img151/3817/img2030large2zi.jpg
http://img151.imageshack.us/img151/557/img2029editlarge2ow.jpg
http://img20.imageshack.us/img20/7963/img2033large3na.jpg

As you can see, it's far from perfect, but it's all there. The broken headlights/grill won't be a problem, as the front end of the 535i is perfect and even has my old euro ellipsoids that I'll be swapping over.

I've wanted to do a project like this for a long time...I always loved my 535i, but I haul a lot of crap around pretty frequently, and who doesn't love the classic lines of the E34 Touring? I've always thought the big, torquey M30, combined with the 5-speed manual tranny, made for the best combination of performance and low operating cost of any E34 drivetrain, and combining that with the Touring body is my personal 'realistic' E34 dream car. :redspot

So, this is the plan for the final output:
1992 BMW 535iT
M30B35 engine
5-speed manual tranny
3.46 LSD rear axle
Sachs kit (this is still up in the air)
M5T sways (19/25mm)
Euro ellipsoids

[Mr Project]

6/22/06 Progress

Today I got the Touring towed to the house, so I have both cars at my 'shop', I did a little cleaning on the Touring, and got the front end disassembled:

From this:

http://img67.imageshack.us/img67/5571/img2040editlarge4sf.jpg

To this:

http://img20.imageshack.us/img20/6195/img2041large2pu.jpg

It'll be a little while before my next update since I have some 'around the house' projects I need to do this weekend. But I promise regular updates and as many pics as imageshack will let me host. :)

[onewhippedpuppy]

Why don't you turbo that M30 while you're in there? That would make for a sweet touring.:evil2 Nice project, should be a cool car when you're done.

[Mr Project]

Yeah, a turbo might eventually be in the plan, butfor the moment I have to be careful about how much $$ I spend on this. I'm also restoring a 40-year old Corvair and that's my 'real' project I want to focus on this year. This will just be the DD.

[Grim Reaper]

Awesome project you got there! :alright

Take tons of pics and keep us posted on the progress.

[Dark Helmet]

you do realize that this again puts you at "three" project cars... right?????

although the natural course of this should reduce it to 2....

and yes yes, turbo, ftw!

[xatlas0]

Awesome! Please, keep up updated. It is good to see some real hot rodding going on, not just "hey, where can I get M5 bumpers for cheap" and other superficial things of that ilk.

[Mojo325is]

hehehe.....

[e39dream]

kick ass! good for you- the resurrection of a bimmer always touches my heart:) I'd like to start a project like this next summer, only with a sedan as the desired daily driver.

[Chigga]

nice project!

are your turbo Swedes Saabs or Volvos?

[flyeryan]

Mr. Project-
Your PM box is full. I'd like your doors from the 535 if possible. Please PM me.

thanks,
Ryan

[Mr Project]

are your turbo Swedes Saabs or Volvos?

Yes. :) A '93 9000 CSE with a 3" turbo-back and a little extra boost, and my daily beater, a 418,000 km-young 744T.

[E34N]

Nice... please keep us updated..

(subscribed!!! :eatpop:)

[LJSE34]

that's a great idea, I want one too!

[Goat128]

touring... what better place to but some nos bottles

[forsaken]

[QUOTE=Goat128]touring... what better place to but some nos bottles[/QUOTE5

Not to get off track.. but call it nitrous... Nos is a company and it sounds F&F to call it that.

But yeah, i love the project! lets get this german grocery getter into a bad ass turn key beast!

[AndrewH]

How about I send you my U.S. ellipsoids and you send me the 2 Euro Smiley lights??

[jfranke]

Cool project! I wish I had the time/money to do something like that.

Good luck

[Mr Project]

Today's progress...the important this is that I got the window installed in the house...just had a little time to strip the Touring down some more.

http://img45.imageshack.us/img45/9313/img2062large1dz.jpg

[HE53]

:buttrock I've been watching... figured I'd post. Lemme know if you need a hand with something one day.. I wouldn't mind coming up and checking it out.

[tempestv8]

:eek: Wow, how do you remember where all the bits and pieces are when you need to put it all back together again!

Awesome project. Keep the photos coming! :buttrock

[e39dream]

the pics will help when it comes time to rebuild, but once you take a car apart like that it doesnt require a ton of thought to put it back- like riding a bike.

[Mr Project]

Yeah, you can see a few green masking tape tags on the harness, I usually make tags for the harness to help me re-route it, and I ziploc baggie the nuts and bolts into general areas and label them. It's not as exact as it sounds, but it helps.

But like E39 said, once you've done something like this a few times, you get a 'feel' for how things go back together and it's not a big deal, just really time-consuming.

After a couple more hours today, I'm ready to pull the M50 out of the Touring. It looks like I'll have some time off from work to focus on this project in a couple weeks, so hopefully I'll be able to make some real headway on it then. Right now I'm limited to a couple hours at a time.

[Dark Helmet]

I'm working late every night this week... GAAAH!

no time for wrenching.

[Dark Helmet]

Yes. :) A '93 9000 CSE with a 3" turbo-back and a little extra boost, and my daily beater, a 418,000 km-young 744T.


you forgot that the 744 was a 4.5spd manual car.

[xatlas0]

I'm working late every night this week... GAAAH!

no time for wrenching.

Yeah, that is what I thought too, then the next thing I knew, it was 2am and I had a completely dissassembled M30 all over my garage floor. (except for the crankshaft, I can't get the dang main nut off! I don't want to heat it, as the whole area is oily and I don't want a M30 torch in my garage)

As a side note, anybody want some Euro M30B30 pistons? 9:1 CR, 90mm bore. Also have a M30B30 head (euro) so it has a hotter cam than the later M30s.

[Dark Helmet]

I wonder if that head would bolt to my B34 bottom end... hmmmmmm.

and I'm not working on my car this time... I'm just helping destroy someone else's car.

[xatlas0]

I wonder if that head would bolt to my B34 bottom end... hmmmmmm.

and I'm not working on my car this time... I'm just helping destroy someone else's car.

http://aaron.aussiefiverdriver.com/M30%20engine.htm

Based on that, I am not so sure. Don't want the pistons banging the head. Of course, I would imagine a machine shop could easily fix that problem...

[Dark Helmet]

I'll check that out later....no biggie though, I'm supposed to be selling the car anyway.

[NascarSigEp]

Looks like a fun project sir. :buttrock

[Mr Project]

Well, here are a few pictures to tell a few thousand words. Progress is moving along pretty nicely, I believe I have less than 10 hours of work into it so far and it's actually mechanically pretty much stripped as far as I can take it for the moment. I will be rebuilding pretty much all the suspension, and pulling most of the interior out for the pedal and heater core install, but for the moment I need it to stay mobile, so I'll probably work on stripping down the sedan next:

M50 almost ready to pull:
http://img397.imageshack.us/img397/9701/img2088large4va.jpg

M50 halfway out:
http://img164.imageshack.us/img164/5934/img2090large4yw.jpg

M50 in it's new temporary home (This is a truck that gets used as a truck! :) ):
http://img392.imageshack.us/img392/9464/img2095large3ui.jpg

I'm EXHAUSTED! Heh.....ok, not funny:
http://img397.imageshack.us/img397/976/img21012vg.jpg

Ready for a real engine (sorry 525 guys :) ):
http://img480.imageshack.us/img480/9081/img2102large0ut.jpg

[Dark Helmet]

droooooooooooooooooooooooooooooooooooooooool....

[Dark Helmet]

Best part of the evening: when the neighbor comes over and says "we knew it was only time before he tore apart another car in the driveway..."

:rofl

that was classic.

[Raff]

Wow that is some project.

[tempestv8]

In Europe, you can get an even smaller engine than the 520i - and that's the 518i. Sure you don't want to do something different by putting in a "different" engine? :stickoutt

Seriously though, thanks for sharing the work-in-progress pictures. I will watch this thread with baited breath.

I just don't have the same mechanical aptitude or guts to do what you are doing so I really do admire your project so far. :buttrock

[Mr Project]

Patience is the real key...if you watch Dark Helmet and I work on something, I look like I'm moving in slow motion compared to him, but I get done in less than half the time. :)

And yeah, I thought about trying to make something like a 518ixTa, but I didn't think I could handle all the power. :)

[Dark Helmet]

"ixTa" :rofl

and that is sooooooooo true re: "look like I'm working at half the speed"....


except on brakes (Discs) we are about even on that one... oil changes too.

[Goat128]

Not to get off track.. but call it nitrous... Nos is a company and it sounds F&F to call it that.

But yeah, i love the project! lets get this german grocery getter into a bad ass turn key beast!

are you suggesting he turn it into a drifter? :lol

j/k

[Dark Helmet]

with the right brake biasing.... it could be done!

[Dark Helmet]

whats with the "no update?!?!?!?!"

[Mr Project]

Sheesh, you're so needy. :)

No, this won't be a drift car. I did order $803 worth of parts from BMA last night, though, and I decided on the Koni/Eibach combo for the suspension. Hopefully it'll go well with the M5T swaybars. I was hoping to do a full suspension rebuild including all bushings and everything, but I just can't afford it right now, so some of the bushings will have to wait a while.

Last night I got the donor car partially stripped. Hoping to have the engine out of it by this Saturday.

http://img233.imageshack.us/img233/8438/img2106large5ea.jpg
http://img238.imageshack.us/img238/2373/img2112large0pp.jpg

[Dark Helmet]

good, good...

what did you order from BMA????

[Mr Project]

Radiator
Fan Shroud
Clutch Pivot Pin
Clutch Slave Cyl.
Driveshaft Center Support
Dogbones
Rear shock mount
Rear brake rotor
Oil Pan gasket
Timing Chain
Timing Chain Link
TChain Tensioner rail
TChain plastic guide rail
TChain case gasket set
TChain tensioner (piston)
Tranny mounts
Heater core
Heater core o-rings -
Heater core o-rings - 13.9mm
Microfilter
Expansion Valve
Rear bump stops
Front bump stops

[mosportgreen66]

Mr. Project, nice work my man.

On the touring car, I would clean that engine compartment with the power washer if it has not been done already.

I have never seen this done on new(er) style BMW's before. Interesting to say the least.

-Dan

[jfranke]

That looks like a clean engine, although you can't judge an engine by the outside...how many miles on that one?

It looks like you're having too much fun:stickoutt I would love to take mine allllll apart and fix all the little problems while upgrading parts as well, but I just can't seem to get my hands on enough of that money I here so much about:(

[Mr Project]

Thanks guys. Yeah, if you look close you can see the powerwasher in the background....it's gonna get some extended application in that Touring engine compartment. I have this thing about trying to have a relatively clean engine compartment...probably because I spend so much time in them. :)

200k on the M30B35, but I owned it from 170-190k and did a HG in that time. You can still see the cross-hatch on the cylinders, it makes great compression, and the head literally looks brand-new.

[El Kabong]

Simply awesome, can't wait to see the results. Being a 5er wagon guy myself, I am stoked!!!

[WebDev]

Wow. Quite a project, but it looks like it is coming along nicely!

[Mr Project]

6/28/06 update:

Doesn't look like much progress tonight, but actually the M30B35 is nearly ready to remove. I just have the shifter and guibo left to disconnect, then unbolt the mounts and away I go.

Not in focus anyway, so this is a little smaller:
http://img249.imageshack.us/img249/7936/img2114medium4cy.jpg

This was the really big news of the night....I never thought in a million years that my little $100 impact wrench would take off the main crank nut. I've been working out all the different options in my head....Build a brace for the rear of the crank while on the engine stand, devise some sort of holding mechanism from the front, borrow a 1" impact from somebody...But I figured, what the hey, before I pack it in for the night I'll give it a shot with my little gun with the air pressure cranked up to 130 or so.

http://img527.imageshack.us/img527/3194/img2116small6ki.jpg

And WHADDYA KNOW! It came off! I'm so shocked, and so excited all at the same time. It's nice when one thing goes your way. :)

http://img527.imageshack.us/img527/1721/img2118small9eo.jpg

So, of course, I immediately had to face the only real hurdle so far. The brackets that are welded to the body are different on the '92 then they are for the '91. It appears that the bracket for the PS reservoir, cruise control, and charcoal canister is totally different on the '92. Take a look:

'91 535i:
http://img523.imageshack.us/img523/299/img2120large24xv.jpg

'92 525iT:
http://img527.imageshack.us/img527/5716/img2121large9zs.jpg

Sorry for taking pics in the dark. When I get closer to reassembly, I'll try monkeying around with different options for mounting the 535i hardware. The only catch is that the PS hoses for the 535i are none too long and they have to stay with the engine that I'm swapping, so I have to find a way to adapt it. I'm really trying to avoid any cutting and welding on this project, but if I have to it won't be the first bracket I've fabricated. :)

[xatlas0]

I am in the same position, sans impact gun. I have been trying to get the dang nut off for a good week, and I don't want to heat it or drill it. I need to get the crank out of a M30B30 I have laying around. I guess I need to take the plunge on air tools finally. :devillook

[Dark Helmet]

IR makes a $350 impact that makes something like 1100ft-lbs in reverse... or so sayeth Armen...



that would be fun.

[Rob Levinson]

Awesome project, good luck with it.

When I saw the first few pics, I really thought you were going to tackle it from "the other end"... cut off the back of the Touring and Sedan, and just use body work skills to accomplish the same end result. More body work, but eliminates all the fiddly differences between M30 and M50 support systems.

Out of curiosity, what did you pay for each of the cars?

- Rob

[Mr Project]

Thanks, Rob. Let me know if you want to donate a short shifter or something to the cause. :D I have to admit, I've considered the bodywork route more than once. But, I've also done enough bodywork myself that I knew this would be a better final result. :) I'm much better with a wrench than with sandpaper.

On the cars, as an ex-owner of the 535i I got the 'good buddy' deal and basically bought it for the scrap buy-back price from the insurance company. The Touring I actually paid they guy a little more than he asked for...he's a friend and I felt like it was worth a little more than his first price. Bad negotiator, I know, but I sleep better this way.

[4500 RPM]

Thanks, Rob. Let me know if you want to donate a short shifter or something to the cause. :D I have to admit, I've considered the bodywork route more than once. But, I've also done enough bodywork myself that I knew this would be a better final result. :) I'm much better with a wrench than with sandpaper.

On the cars, as an ex-owner of the 535i I got the 'good buddy' deal and basically bought it for the scrap buy-back price from the insurance company. The Touring I actually paid they guy a little more than he asked for...he's a friend and I felt like it was worth a little more than his first price. Bad negotiator, I know, but I sleep better this way.

Bad negotiator, good friend. That's a good way to be.

I'm looking forward to watching this project progress.

[Rob Levinson]

Thanks, Rob. Let me know if you want to donate a short shifter or something to the cause. :D

I don't know about "donate", but I've got a freshly rebuilt Cartech twin turbo kit for the M30 that you can have at a very reasonable price.


The Touring I actually paid they guy a little more than he asked for...he's a friend and I felt like it was worth a little more than his first price. Bad negotiator, I know, but I sleep better this way.

Much better - you keep the car and the friend.

- Rob

[Dark Helmet]

Rob, you have no idea how funny your turbo comment is...

I don't think there has been ONE DAY go by since the 535 was totalled (we've known of the Touring for a while) that someone hasn't harassed Armen about a turbo......




also: it really DOES need a shifter, the 535 shifter is all original, never touched, and has something like 225,000 miles on it... I've driven it, and I'm telling you.... DONATE THE MAN A SHIFTER!!!!! (or at least throw it in at cost when he buys the turbo stuff!!! :D:D:D )

[Rob Levinson]

Rob, you have no idea how funny your turbo comment is...

I don't think there has been ONE DAY go by since the 535 was totalled (we've known of the Touring for a while) that someone hasn't harassed Armen about a turbo......

Gotta have a turbo with the M30. Especially in a car so interesting as a 535iT. :D




also: it really DOES need a shifter, the 535 shifter is all original, never touched, and has something like 225,000 miles on it... I've driven it, and I'm telling you.... DONATE THE MAN A SHIFTER!!!!! (or at least throw it in at cost when he buys the turbo stuff!!! :D:D:D )

I bet it does need it! Sounds like a deal - buy my turbo, I'll throw in the shifter.

- Rob

[Mr Project]

Yeah, and let's just say that my total budget for the project, including purchase prices of the cars, is probably less than one fairly complete turbo setup. I'm a ways out from having that kind of $$ to spend on this car...I gotta finish a Corvair first. :)

There was actually a brief 'scare' a year or so ago where I thought I was going to get an E34 540i/6 donor car for this project....frankly I'm happier this way, as I'm way more comfortable with the M30, and the dangling turbo-shaped carrot will keep me interested for a while. :)

[Mr Project]

Gotta have a turbo with the M30. Especially in a car so interesting as a 535iT. :D

I bet it does need it! Sounds like a deal - buy my turbo, I'll throw in the shifter.

- Rob

Dang, you're killin' me! Now if I could just get a side job in all my spare time... :)

[Dark Helmet]

:rofl

thanks rob.

there might be another 535i on the block soon Rob... we'll keep in touch... :evil2

[Dark Helmet]

Dang, you're killin' me! Now if I could just get a side job in all my spare time... :)


it can't be too much longer until Froeming destroys another car he can't fix and you can...

and we should start doing brake-jobs and tune-ups on saturday mornings on all manner of things... you could also make a killing synching carbs on old european stuff.

OR... you could get that promotion.....

[Rob Levinson]

Yeah, and let's just say that my total budget for the project, including purchase prices of the cars, is probably less than one fairly complete turbo setup. I'm a ways out from having that kind of $$ to spend on this car...I gotta finish a Corvair first. :)

Have you got $2K to spend? :D

- Rob

[Mr Project]

Have you got $2K to spend? :D

- Rob

Holy crap. And no, but holy crap. :mad

[Dark Helmet]

he doesn't, but I might....

[xatlas0]

Oh man, now that is tempting to put on the E9!

...but out of respect for Mr.Project and his... project... I'll leave it to him.

Out of curiosity, what are the specs on that kit?

[bimmerbuddy530i]

Yes do tell please.

[Dark Helmet]

also, armen: "HOME EQUITY LINE OF CREDIT" :D:D:D

[Mr Project]

Oh man, now that is tempting to put on the E9!

...but out of respect for Mr.Project and his... project... I'll leave it to him.


As much as I would love to, I genuinely can't afford to at this point....Unless I cancel the paintwork on the Corvair...but no, I really can't. So don't hold off on my account.

I'd love to see the specs on it too, so that I might torture myself further.

[323I Junkie]

Ah guys..good to see you are at it again.

I wish I was working on anything right now, but currently Robots rule my life, that and a very slow contractor :(



The 535iT will be awesome....I want one...or a 735i/6


anyway, looks like an incredible amount of work


I would look real seriously at a MAF conversion, a header, and leave it at that....Thats what Im doing on the e34..the e23 however :devillook:

[dirtye30]

Wow, I love the E34 tourings. You never see one thats clean and hooked up, unless its a M5t in europe those lucky bastards. I am subscribing. I wish I had the time and the wrenching skills to throw an M30B35 in my e30.

[323I Junkie]

Yeah, being so in love with the V12...I dream about a 550iT or 553iT or even a 560iT (Not the new 6.0 but the built one from the m73 block)

[Mr Project]

Yeah, the first time I looked at that bare engine compartment in the Touring, I thought...hmmm....a M70/73 would fit just fine in there... :)

[Dark Helmet]

Abe.... are you doing naughty things to teh L7??????


spill the dirt via PM or I'll have the admins block you from this forum! :D:D:D

[Mr Project]

6/29/06 update:

Well, it took over 2 hours tonight, but I did get the motor out of the 535i. Dark Helmet came by and helped some, and his 1yo kid supervised quite a bit. :) I managed to mangle my wrist and jaw a little, and got a few nice little bruises as well. This project had just been too easy and injury-free up to this point. :)

http://img236.imageshack.us/img236/7344/img2128small4xf.jpg
http://img212.imageshack.us/img212/1344/img2130small2jt.jpg

Here's a question: Can I get away with using the M50 engine mounts? Here is my totally hosed M30 mount:
http://img409.imageshack.us/img409/3669/img2124small4mc.jpg

And the pretty good-looking M50 mount:
http://img272.imageshack.us/img272/6885/img2126small4oy.jpg

I'll take some measurements tomorrow or Saturday. I don't mind a little extra stiffness, since the 535i mounts are obviously multi-piece partly for vibration purposes.

[Dark Helmet]

6/29/06 I managed to mangle my wrist and jaw a little, and got a few nice little bruises as well.


YOU DROPPED AN M5T-SPEC SWAY BAR ON YOUR FACE..... DUDE, I HEARD THE METAL go CLANG AGAINST YOUR GRILL!!!!!




all said, pusing engine/trans-less E34s around>doing so with engines still installed... ftw!

good progress man, take a couple dozen advil and tomorrow night off... all will be well. Linus says "anti-freeze tastes good!" :rofl

[Dark Helmet]

you can file that under the "amplified version"

[323I Junkie]

Ive said it before, Ill say it again, I wish I was there to work with you guys. Im powerless to, to though :(

Yeah, el seven-hell seven. It ll be my last project till im 36 or so :eek:

[Mr Project]

Wish you were here too, junkie. Though it'd just mean that I'd spend more money on these 4-wheeled mistresses. :)

I noticed yesterday that there are signs of rust under the paint in one of the rear wheel wells on the touring. Sigh. So, next year I might be doing a bit mroe paint work on it than I had planned.

[Rob Levinson]

Oh man, now that is tempting to put on the E9!

...but out of respect for Mr.Project and his... project... I'll leave it to him.

Out of curiosity, what are the specs on that kit?

It's a Cartech setup, very similar to the Alpina BiTurbo design. It uses two T-03 turbos, both rebuilt right before I acquired the kit. It includes the manifold, the turbos, downpipe (configured for a 635CSi, will probably need a new one made for E34), manifold tube with additional fuel injector fitted, and heatshield. The hard tubes could use some cosmetic refinishing (somebody thought the aluminum tubes would look good refinished in purple). I acquired the kit with a mechanical RRFPR, but I would recommend some modern control electronics.

I originally acquired it for an E32 735iL project, which I've decided not to pursue (and I have the mechanically perfect 735iL for sale if interested).

Pic:

http://www.robertlevinson.com/twinturbo/Image1.jpg

- Rob

[Dark Helmet]

how much do you want for the E32???? I might have a buyer.

and as for the turbo... it it is setup for a 635CSi... that would make it ideal for a bastard-child 533/B34 swap in dire need of a maf conversion or MegaSquirt....

correct?

especially in a state with no emissions enforcement.....

[xatlas0]

It's a Cartech setup, very similar to the Alpina BiTurbo design. It uses two T-03 turbos, both rebuilt right before I acquired the kit. It includes the manifold, the turbos, downpipe (configured for a 635CSi, will probably need a new one made for E34), manifold tube with additional fuel injector fitted, and heatshield. The hard tubes could use some cosmetic refinishing (somebody thought the aluminum tubes would look good refinished in purple). I acquired the kit with a mechanical RRFPR, but I would recommend some modern control electronics.

I originally acquired it for an E32 735iL project, which I've decided not to pursue (and I have the mechanically perfect 735iL for sale if interested).

Pic:

http://www.robertlevinson.com/twinturbo/Image1.jpg

- Rob

Does it come with a tune, or will a custom tune be required? No intercooler?

[Rob Levinson]

how much do you want for the E32???? I might have a buyer.

It's a 1988 with approx. 230K on the chassis, 1 previous owner. Over-maintained and has all-new self levelling suspension. A bad DME leaned out one cylinder, burning the pistong... so I replaced it with a 65K-mile motor and new DME. Also installed lowering springs and a fresh alternator, battery, and a bunch of other maintenance items. It is mechanically flawless, everything works and it drives great.

Cosmetically, it's had a partial re-paint that you can see, the rear section is slightly darker. The leather is a bit tired and shows the surface cracking typical of these older models. 15" alloy wheels show typical paint damage from wheel cleaner and embedded brake dust.

She's a runner, not a looker. :D

$2500 gets you a car that needs nothing.


and as for the turbo... it it is setup for a 635CSi... that would make it ideal for a bastard-child 533/B34 swap in dire need of a maf conversion or MegaSquirt....

correct?

especially in a state with no emissions enforcement.....


Absolutely! The installation is the same on any M30.




Does it come with a tune, or will a custom tune be required? No intercooler?

Does not include any software or engine management or intercooler. A rising-rate fuel pressure regulator (RRFPR) is the "dinosaur" method of controlling a turbo, but an add-on Megasquirt or HKS will give substantially better results.

If somebody wants both the E32 and the turbo kit, we can definitely work a deal!

- Rob

[brosher]

Hey cool thread, i'll be tagging along.

Has anybody claimed the interior from the 535 yet? I think I am going to buy a 535 w/ the dreaded smurf interior this weekend...

[Rob Levinson]

Wow, I love the E34 tourings. You never see one thats clean and hooked up, unless its a M5t in europe those lucky bastards.

Did someone say M5T? :D

http://www.robertlevinson.com/M5_Touring/visuals/sidebw.jpg (http://www.robertlevinson.com/M5_Touring/)

- Rob

[Dark Helmet]

way to rub it in Rob...

and Rob, you have any idea what it would take to fit a 5-speed to that E32?

[xatlas0]

Did someone say M5T? :D

http://www.robertlevinson.com/M5_Touring/visuals/sidebw.jpg (http://www.robertlevinson.com/M5_Touring/)

- Rob

Do you want some lemon to rub in with that salt?

As a side note, the injector on the intake pipe, does that mean the system originally came with an entirely new engine harness?

[Rob Levinson]

and Rob, you have any idea what it would take to fit a 5-speed to that E32?

Sure, simple enough: Getrag 260 or 265 gearbox (or 280 from the M5, or 280/6 six-speed from '95 M5 :D ), 735i 5-speed pedal box and miscellaneous clutch lines, flywheel & clutch kit (I recommend E34 M5 single-mass flywheel and M5 clutch), custom driveshaft from Beyer Motor Works (<$700, my guess), 735i 5-speed shifter carrier and linkage, 735i shift boot (should snap into automatic frame), and a UUC shifter assembly.

- Rob

[Rob Levinson]

Do you want some lemon to rub in with that salt?

Jeez, I was just posting a picture, not ordering a shot of tequila! :D


As a side note, the injector on the intake pipe, does that mean the system originally came with an entirely new engine harness?

I believe the previous owner was using some other device to trigger the injector, but I do not know what.

- Rob

[Dark Helmet]

Sure, simple enough: Getrag 260 or 265 gearbox (or 280 from the M5, or 280/6 six-speed from '95 M5 :D ), 735i 5-speed pedal box and miscellaneous clutch lines, flywheel & clutch kit (I recommend E34 M5 single-mass flywheel and M5 clutch), custom driveshaft from Beyer Motor Works (<$700, my guess), 735i 5-speed shifter carrier and linkage, 735i shift boot (should snap into automatic frame), and a UUC shifter assembly.

- Rob


interesting... only the driveshaft is making me choke... any reason a good drive-shaft shop can't alter the stock automatic piece (or does it need to be longer?)

and which gearbox is from the E34????

[Rob Levinson]

interesting... only the driveshaft is making me choke... any reason a good drive-shaft shop can't alter the stock automatic piece (or does it need to be longer?)

and which gearbox is from the E34????

Sure, a driveshaft shop should be able to alter the existing driveshaft.

The E34 535i and 735i 5-speed use the Getrag 265. I suggested the 260 and 280 because they are physically interchangeable. 260 is the earlier version (smooth case, no cooling fins) and 280 is the beefier M5 version.

- Rob

[Goat128]

Did someone say M5T? :D


- Rob

Sorry for the ot but is that two-tone (the grey underneath), original?

[Rob Levinson]

Sorry for the ot but is that two-tone (the grey underneath), original?

Yes. Almost all M5s were delivered with one of four lower trim colors, three types of silver and anthracite.

- Rob

[Dark Helmet]

really... I was told the 260 (IIRC 260/5) from my E28 was not a direct bolt-up....


iiiiiiiiiiiiiiiiiiiiiiiiiiiinteresting....

[Rob Levinson]

really... I was told the 260 (IIRC 260/5) from my E28 was not a direct bolt-up....


iiiiiiiiiiiiiiiiiiiiiiiiiiiinteresting....

Advice from a message board? :lol

[Dark Helmet]

ok, I got it... I was asking a different question... the 260 is not a direct replacement for the 265, it will, however, bolt up to the motor just fine... the different tail-shaft dimensions/particulars are the issue.

my brain hurts....

[Rob Levinson]

ok, I got it... I was asking a different question... the 260 is not a direct replacement for the 265, it will, however, bolt up to the motor just fine... the different tail-shaft dimensions/particulars are the issue.

my brain hurts....

To clarify my answer, I believe they are directly interchangeable. Slight differences in tailshaft length are accomodated by the extensible section of the driveshaft. Immaterial if you're having a custom driveshaft made anyway.

- Rob

[Mr Project]

735i 5-speed pedal box and miscellaneous clutch lines, 735i 5-speed shifter carrier and linkage, 735i shift boot

Rob, correct me if I'm wrong, but couldn't all these parts also be sourced from an E34 535? IRRC all the under-dash stuff was the same from E32-E34. It would make the junkyard search a lot easier.

[dirtye30]

Did someone say M5T? :D

http://www.robertlevinson.com/M5_Touring/visuals/sidebw.jpg (http://www.robertlevinson.com/M5_Touring/)

- Rob

skeet skeet (sorry joe boxer) yeah, thats effin hot.

[Rob Levinson]

Rob, correct me if I'm wrong, but couldn't all these parts also be sourced from an E34 535? IRRC all the under-dash stuff was the same from E32-E34. It would make the junkyard search a lot easier.

Possibly. I haven't compared the p/n list, I've still got E38 manual swap on the brain.

- Rob

[jfranke]

ha ha, I'm enjoying this one, keep it up guys.

[Rob Levinson]

skeet skeet (sorry joe boxer) yeah, thats effin hot.

:D I know an awesome detailer. Hate to drive it after he finishes... but it's an M5, it's meant to be driven:

http://www.robertlevinson.com/M5_Touring/images/details_details/

- Rob

[xatlas0]

Isn't the Getrag 260/5 used in everything after 1985, rather than the 265?

DH- driveshaft shops are everywhere. The driveshaft length can actually be found usually on reloem, they have the length in mm in the description section. The 260 is 4mm longer or shorter than the 265, if I recall right.

[323I Junkie]

the e34 735i Turbo 6 speed is my dream, black car, dove grey interior.soudns system identical to my car, sachs kit, UUC clutch and shifter, hella black tails, black turns, ellipsoids, tint, flat exhaust tips, two, like a 750 3.46 LSD with nitrous.

thats all, thats all i want, or a750 like robs

i dont want the iL in the e34, i thought i did, then i drove one but thre room is nice

[WebDev]

More pics of the project!

[Dark Helmet]

re: "realoem"

the 5-speed iL never existed... hence the need for "custom"

man I need a new car... BAD.

[autophile]

Nice... please keep us updated..

(subscribed!!! :eatpop:)


+1

[attack eagle]

Fantastic! And extremely educational... I'm staying tuned.

[Mr Project]

This just in. The M50 mounts are 1/2" shorter than the M30 mounts, so I don't think I can use them. I don't want to take a chance that the change in driveshaft angle would cause vibration issues...so I'll have to pony up for the M30 mounts. Oh well, another $90 down the tubes!

[Mr Project]

7/1/06 update:

Not much got done today...mostly cleaned things in preparation for a big 4th party tomorrow. Did get the Touring engine compartment cleaned up, though:
Before:
http://img480.imageshack.us/img480/9081/img2102large0ut.jpg
After:
http://img240.imageshack.us/img240/2706/img2132large4pw.jpg

I also had a little trouble while cleaning up: See anything wrong with this?

http://img240.imageshack.us/img240/3540/img2142small7eq.jpg

Um, yeah, that's the key, and the locked door, and the rest of the doors are locked too. Fortunately my neighbor is a locksmith and owed me a favor, so he got it open. D'oh!

[323I Junkie]

AWesome..good thing buying the mounts

I just rebuilt the engien in the e23..repalced everything..hoses, injectors, mounts...wire ends, harness looms, wires, every clamp, everything...youll have a new bimmer

[cvx5832]

Good job cleaning the engine bay on the Touring. It's really coming together there.

[islandbeef]

Yow, that engine bay looks brand new. Can't wait for the transplant. :)

[attack eagle]

was that jsut pressure washed? or hand washed on top of pressure washed? Either way it looks fantastic...

[Mr Project]

I sprayed it down with degreaser, scrubbed it with a brush a little bit, and then just worked it over with the pressure washer (for at least 30 minutes!). The only problem was that the brush I used made some very light scratches in the paint. Not that anybody else would really notice, but it'll bug me. :mad

[323I Junkie]

I ve tried simple green, orange, eerything...they seem to leave a residue of sorts

what degreaser? Gunk still works best, but the smell is FTL

[gtopaul]

Since I just did an engine swap into my 92 525iT (M3 S52) I was wondering about the M5T sway bars. I ordered the M5 touring sway bars for mine too, should be here Monday or Tuesday. Someone mentioned, after I had ordered them, that the front sway bar isn't notched to clear the automatic transmission support bracket which attaches to the crossmember (the big U-shaped bracket that bolts to the bottom of the trans). Of course the M5s didn't come with automatics. I kept my automatic but didn't reinstall that bracket because there was a later SI that pointed at the bracket for causing vibration problems in the E34. So, if the M5 bar isn't notched it looks like grinder or sawsall time to remove the brackets from the crossmember. Just another fact, the M5 bar is the same diameter as the 92 Touring front bar anyway so I'm not sure there's any real gain to be had. The rear bar is bigger on the M5 Touring. Guess I'll find out for sure when the bars get here.

It's a real job taking the engine and trans out from the front. Luckily I have access to a lift and just dropped the entire front suspension with engine and trans from the bottom onto a dolly. Had the swap done in a day but I planned it that way thus the easy S52 swap. Anyway, keep up the good work and keep up the updates!

Paul L

http://members.aol.com/gtopaul/private/50015.jpg

[4500 RPM]

Since I just did an engine swap into my 92 525iT (M3 S52)



HOLY CRAP!

Make a seperate thread with lots and lots of pics! :buttrock

[Dark Helmet]

I'm gonna take pics of the front of MY house... I seem to have become Mr. Projects alternate Parking Facility.... :rofl

j/k man... bay looks great, and the mounts are better done now than later.

just get over the fact that you under-budgeted this thing by a grand.... :D:D:D:D

[Mr Project]

just get over the fact that you under-budgeted this thing by a grand.... :D:D:D:D

Yeah, what else is new?! :D

[Mr Project]

My excuse for no good updates lately: A "Mr Project" in its natural habitat:

http://img216.imageshack.us/img216/6214/img2147small6tk.jpg

[Mr Project]

Since I just did an engine swap into my 92 525iT (M3 S52) I was wondering about the M5T sway bars. I ordered the M5 touring sway bars for mine too, should be here Monday or Tuesday. Someone mentioned, after I had ordered them, that the front sway bar isn't notched to clear the automatic transmission support bracket which attaches to the crossmember (the big U-shaped bracket that bolts to the bottom of the trans). Of course the M5s didn't come with automatics. I kept my automatic but didn't reinstall that bracket because there was a later SI that pointed at the bracket for causing vibration problems in the E34. So, if the M5 bar isn't notched it looks like grinder or sawsall time to remove the brackets from the crossmember. Just another fact, the M5 bar is the same diameter as the 92 Touring front bar anyway so I'm not sure there's any real gain to be had. The rear bar is bigger on the M5 Touring. Guess I'll find out for sure when the bars get here.

It's a real job taking the engine and trans out from the front. Luckily I have access to a lift and just dropped the entire front suspension with engine and trans from the bottom onto a dolly. Had the swap done in a day but I planned it that way thus the easy S52 swap. Anyway, keep up the good work and keep up the updates!

Paul L


Paul, 'easy' swap or not, I'm seriously impressed that you got it done in a day! Thanks for the word of warning on the swaybars, I'll take a closer look at how that will go back together. I'll have to decide whether to cut off the brackets on the Touring crossmember or just swap over the crossmember from the sedan.

I'm also fairly certain that the M5 25mm front swaybar is larger than the stock Touring piece. I'll have to measure them both tomorrow and see, but after getting hit in the face with the M5 bar, I want to say it's quite a bit heavier. :)

[Rob Levinson]

Thanks for the word of warning on the swaybars, I'll take a closer look at how that will go back together. I'll have to decide whether to cut off the brackets on the Touring crossmember or just swap over the crossmember from the sedan.

ETK shows only one part number for the front cross member which apparently is the exact same part on every E34 from 525 to M5, no distinction between automatic or manual.

Of course, that doesn't mean the cars weren't built with different parts. It's not unusual for a single supercession in the ETK to make a single part number work where multiple parts were originally used.


I'm also fairly certain that the M5 25mm front swaybar is larger than the stock Touring piece. I'll have to measure them both tomorrow and see, but after getting hit in the face with the M5 bar, I want to say it's quite a bit heavier. :)

Interesting that both the 525i Touring and M5 (and 535i with M Sport susppension) use a 25mm front swaybar... but differerent in some aspect as there are two different part numbers. I suspect this is the automatic clearance that gtopaul noted. No other differences - same bushings, same endlinks, etc. The M5 does not, as far as I know, use different swaybar mounting points as it is common to replace the struts with aftermarket units spec'd for the 535i. Net result is that you can probably use the automatic version of the 25mm swaybar with identical results to the M5 version.

I am curious if you actually find a weight difference - that would mean the 525i bar is hollow, which would surprise me. It's quite expensive to make a hollow swaybar and no reason for offering such hardware on a 525i comes to mind. Please do share the results of your measurements.

- Rob

[323I Junkie]

My excuse for no good updates lately: A "Mr Project" in its natural habitat:

http://img216.imageshack.us/img216/6214/img2147small6tk.jpg


all that barbecue, and a diet coke

[Rob Levinson]

all that barbecue, and a diet coke

That's not a barbecue, it's a high-temp parts cleaner. :D

- Rob

[Mr Project]

You laugh, but what do you suppose I use for removing 40-year-old rubber bushings from Corvair suspension parts? :D :D

[Dark Helmet]

all that barbecue, and a diet coke


easy there abe... armen and regular soda=bad.

[Dark Helmet]

You laugh, but what do you suppose I use for removing 40-year-old rubber bushings from Corvair suspension parts? :D :D


whatever it is I can usually smell it hanging in the air for 1-2 days afterward... I'm surprised the EPA nazi on our street hasn't protested yet!!!!

[323I Junkie]

easy there abe... armen and regular soda=bad.


oh bummer...I thought it was a health thing. So is this a pre-fourth of july warm up?

[Dark Helmet]

oh bummer...I thought it was a health thing. So is this a pre-fourth of july warm up?


I'll let armen detail it all for you, it's his metabolism.

[Mr Project]

oh bummer...I thought it was a health thing. So is this a pre-fourth of july warm up?

Yeah, I'm hypoglycemic. No biggie, but after 10 years of drinking the diet stuff, the regular stuff is NASTY. And yes, this was the 'family' 4th celebration, the 'friends' one is tomorrow night.

Rob, I know the crossmember (the piece between the rear mount of the thrust arms) is different between the Touring and the sedan in my case...the Touring has brackets for that auto tranny mount that Paul was describing, and the sedan does not. I'll get some pictures to share. I kinda wanted to use the thrust arms/control arms/steering links from the sedan anyway, since I know they are good, so I might just swap the whole subframe over.

I'm really curious about this swaybar thing now too, so I'll have to check that out when I get home over lunch.

[Dark Helmet]

you gonna drop the touring's bar on your head to see which one hurts more???? :D:D:D:D

[Mr Project]

Rob and Paul are right, the Touring bar is the same diameter as the M5 bar, and actually slightly heavier due to the shape, I think (Touring bar at bottom):

http://img482.imageshack.us/img482/6243/img2170medium4wi.jpg

This is the bracket difference I was talking about:

Touring (M50 auto):
http://img482.imageshack.us/img482/9313/img2168medium6ok.jpg

Sedan (M30 manual):
http://img225.imageshack.us/img225/6271/img2166medium0ft.jpg

I call it the crossmember for lack of a better term, but it's not the 'main' crossmember piece.

[gtopaul]

Paul, 'easy' swap or not, I'm seriously impressed that you got it done in a day! Thanks for the word of warning on the swaybars, I'll take a closer look at how that will go back together. I'll have to decide whether to cut off the brackets on the Touring crossmember or just swap over the crossmember from the sedan.

I'm also fairly certain that the M5 25mm front swaybar is larger than the stock Touring piece. I'll have to measure them both tomorrow and see, but after getting hit in the face with the M5 bar, I want to say it's quite a bit heavier. :)

The reason my swap only took a day was because I had the engine on a stand in the shop and spent about two months on the internet getting any morsel of information I could from a number of different forums and people. I just added all the needed parts to the engine while it was just sitting there. When that was as complete as I knew how to do I added the rebuilt automatic to the engine so the whole trans/engine assembly was basically ready to go. I transfered all the engine accessories, exhaust manifolds, intake manifold/throttle body, and engine mounts to the new assembly once the engine was out. That took a couple of hours and then it was all shoved back up into the engine bay. The installation looks like a factory job or like maybe I just changed the engine cover. :D

http://members.aol.com/gtopaul/private/525m3001.jpg
http://members.aol.com/gtopaul/private/525m3002.jpg

Just found out the sway bars are on back order. Guess they'll have to come over from Germany. Your sway bar pics basically confirmed what I thought about the differences. Now I just have to see if the material of the bar is different otherwise I'll probably leave the Touring front bar where it's at.

Thanks!

Paul

[Mr Project]

Paul, based on weight, appearance, 'feel', and other highly scientific methods of comparison, I don't have any reason to believe that the M5 bar is constructed any differently than the Touring bar. I think you'd be fine as-is in the front. Obviously it just hit me in the head a little too hard the first time. :)

[Dark Helmet]

is there a softer front bar???? that could be fun..... :D:D:D

[HE53]

Heres my question...

Can the rear touring bar be put on a sedan?

I have been thinking about doing sways on one of my cars...



Also gtopaul,
What year is your touring? I have been curious about the non vanos cars having an s50 put in them. I will be doing an s50 swap in my manual car after a couple of my other projects are finished.

[WebDev]

Good project, keep the pics coming.

[Dark Helmet]

Heres my question...

Can the rear touring bar be put on a sedan?




it is a direct bolt-up, I believe. Armen's rear M5T bar just came off his sedan.... I helped unbolt it last week.

[Wiseguy ON]

Oh man I gotta start paying more attention to this....

In fact, I think you all need to see my latest acquisition:

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=8077386590&rd=1&sspagename=STRK%3AMEWN%3AIT&rd=1

I'm going to start building up the body on it.. I have also just gotten my hands on a rusty 745i with a nice interior and great drivetrain, I figure combine that with a Getrag 265 and I'm golden.

My E34 project is going slowly, but now that the lift is free this weekend I'm going to yank the drivetrain out of the car and throw a 5-speed into it and turbo the M50 later on.

[Mr Project]

Yes, I saw that in the 7 series forum... and that is SERIOUSLY cool. :) Good luck with that!

I've taken today and tomorrow off from work, so there'll be more updates coming soon. Today is probably going to be focused on paintwork!

[323I Junkie]

How are you goign to do the electrical?

splice in the harness, or strip the harness back into the dash area and replace?

[Dark Helmet]

the engine harness is apparently modular, remove the M50 stuff and replace with M30 stuff.

seems pretty easy.

[323I Junkie]

the engine harness is apparently modular, remove the M50 stuff and replace with M30 stuff.

seems pretty easy.

How big an email can you get? Ive go the entire 1992 e34 factory wiring harness schematic...and unforunately.....its not modular ...its different all the way into the dash :(


bright side is, summers , you guys can help each other out. Nothing like doing a dash nharness alone, I know.

1, 568, 278 wires and 11ty forty connectors, 80 zillion bolts and nuts

[Mr Project]

Oh noes, 11ty forty! :D Junkie, I really think the engine harness is modular, it's the body harness in the engine compartment that is different and goes all the way into the dash. I'm hoping to splice the 535i pieces in, but I thought that would pretty much be limited to the coolant temp sensor (radiator) and the coolant level sensor. The rest of the components (mostly lights) I don't think I have to mess with.

I would love to have the wiring diagram...how big are you talking? I'll pm you my work address.

[Mr Project]

Not just a daily update... a lunch break update! :)

Ok, there are brackets in the 535i engine compartment that are not in the 525i engine compartment. Those brackets are:

Air cleaner holder - M30 version does not exist in M50 car
Ignition coil holder - M30 version does not exist in M50 car
PS / Charcoal canister holder - bracket is shaped totally differently

I've decided to do this 'right'. I've drilled out the spot welds and removed the first two brackets and welded them onto the 525iT. The Calypso engine compartment is the 535i, the Island Green is the Touring:

Spot welds drilled:
http://img521.imageshack.us/img521/181/img2210medium4nf.jpg

Touring prepped with weld-through primer:
http://img254.imageshack.us/img254/8505/img2215medium9kl.jpg

Welded on, welds ground, and a little filler applied to smooth things out:
http://img254.imageshack.us/img254/9004/img2217medium4zg.jpg

Both brackets in place:
http://img521.imageshack.us/img521/3515/img2219medium5hz.jpg

[Dark Helmet]

noice....

[LJSE34]

This is so cool, an almost live engine swap thread. This thread will become a classic.

[Dark Helmet]

especially when he drops ANOTHER sway bar on his face.... :devillook

[Mr Project]

7/6/06 update:

Ok, final progress today is that I got the PS/Charcoal bracket modified and one half of the engine compartment 90% prepped for paint.

Here's the first 2 brackets smoothed out a little:
http://img98.imageshack.us/img98/879/img2220medium6cu.jpg

Here's the PS bracket. You can see that rather than transferring the whole M30 bracket, I decided to cut off just the relevant portion and weld it to the existing M50 bracket:
http://img275.imageshack.us/img275/1411/img2221medium3oa.jpg


This won't be a show-quality paint job, but it'll be a little thicker than the factory job...in the engine compartment they must have blown through pretty quickly. There's not much paint on there!
http://img180.imageshack.us/img180/245/img2224medium4an.jpg

Later tonight I'll get the rust treated so it'll be ready for final sanding and paint tomorrow.

[gtopaul]

Also gtopaul,
What year is your touring? I have been curious about the non vanos cars having an s50 put in them. I will be doing an s50 swap in my manual car after a couple of my other projects are finished.

My Touring is a 92 non-vanos model. It will be a much easier swap starting with the S50 because you won't have to change most of the sensors. I had to change most everything on my S52 to basically replicate the S50 so it would work. Also had to change the engine harness to a later 525i with vanos. Everything connected up fine except the vanos solenoid. The solenoid from a E36 (M3 too) has too short a lead to plug into the E34 vanos harness so you'll have to get one from a E34 (longer lead). The only other concern is getting a 95 M3 DME from a model with a build date earlier than 12/94 or you will run into the EWS problem. You can buy the EWS delete chip from Turner Motorsport that will work on the later DME's though. That's what I did but it's another $300 expense.

Paul

[HE53]

My Touring is a 92 non-vanos model. It will be a much easier swap starting with the S50 because you won't have to change most of the sensors. I had to change most everything on my S52 to basically replicate the S50 so it would work. Also had to change the engine harness to a later 525i with vanos. Everything connected up fine except the vanos solenoid. The solenoid from a E36 (M3 too) has too short a lead to plug into the E34 vanos harness so you'll have to get one from a E34 (longer lead). The only other concern is getting a 95 M3 DME from a model with a build date earlier than 12/94 or you will run into the EWS problem. You can buy the EWS delete chip from Turner Motorsport that will work on the later DME's though. That's what I did but it's another $300 expense.

Paul

Awesome, thanks for your reply. I may be PM'ing you in the future and giving you a call or email with a list of questions. I have an E21 project that I want to do first and then it will be s50 swap for me.

/highjack

[323I Junkie]

On a non vanos model.....It may be possible to bring the COP and MAF technology over to the m30...just thinking about it, most of the sensors are the same....youd have to have custom programming, and take apart then carefully build 10mm wires to run from the valve cover to plug on the m30, LS1 style.....


The SFI of the m50 and the MAF/COP could wake that m30 up in ways you havent imagined...you could use a maf off of a euro m5 or a euro 735 v8....


it would rock....do it Armen

do it do it doit do it

[Mr Project]

Heh, that is SERIOUSLY out of scope for this project. But cool idea. :) If I was going to mess with it to that extent I'd just do a megasquirt and a map sensor. I even already have the megasquirt built in the basement.... :D

[Dark Helmet]

T

U

R

B

O

[HE53]

You guys have completely lost me. I wish I understood all the computer ignition stuff.... I wouldn't be so scared of FI..

[323I Junkie]

and i dont even know of any good books on the subject

[Dark Helmet]

the only tuning stuff I've seen is on older fuel injection and/or is specific to late-model Ford V8s...

[323I Junkie]

I think what is really necessary, and the way I arrange my curriculum,
is an understanding of what is going on in an engine specifically, a little bit of chemistry, a little bit of electronics, then the wy any computer controlled output/input system works. once you get that, it doesnt really matter what you work on, its all the same

[Mr Project]

Well, I'm tired, and today did NOT go very well, but here's a teaser update:

Old 'n Busted:
http://img98.imageshack.us/img98/879/img2220medium6cu.jpg

The New Hotness:
http://img84.imageshack.us/img84/5479/img2241medium8gq.jpg

[attack eagle]

Looks factory to me! You mean it didn't come that way as a one off prototype?

;)

[mottati]

great thread, mr project. Really nice work, i'll look forward to the completion...
Makes me want to go out and get another e34 touring.


gtopaul:

how long have you had your touring. I owned an idential (albeit stock, other than wheels and suspension, but always thought of a S50 swap) cashmere beige 92 touring from 95-99 here in Ca. (not that it's a super rare car, but i often wonder what happened to it).
Mike

[323I Junkie]

I didnt know you could paint?

[HE53]

Lemme guess.. did you have problems with it trying to lift on you?

I would imagine you would have to clean it over and over with soap and water, then over and over with final klean or other laquer thinners to get all that oil etc out of the engine bay.

[Mr Project]

No, the paint actually went fine, it was the engine work today that didn't go well. The oil pan WILL NOT COME OFF. Seriously. I have the engine hanging from a hoist in the garage, and we even took off the tranny, and the oil pan is NOT coming off. I'll post some pics of it tomorrow.

Sure, Abe, I can paint. As long as nobody gets within 15 feet, it usually turns out pretty well. :D

[Mr Project]

For the curious: My paint prep steps were as follows for the engine compartment:

1 - Heavy degreasing with gunk brand engine degreaser and brush
2 - Extended application of 2500 psi powerwasher
3 - Sanding down to bare metal where welding would occur
4 - Weld-through primer applied to welding areas
5 - Brackets welded on
6 - More sanding of areas where surface rust was forming (under brake booster, under washer fluid reserviour)
7 - POR-15 rust converter/treatment (2 stage process, metal prep first)
8 - Whole engine compartment wetsanded with scotchbrite and 200/400 grit sandpaper - all areas scuffed at least to take shine off top coat
9 - Masked off
10 - Final wipe down with DX-440 Wax/Grease remover
11 - Paint - 4 coats of single-stage Omni MTK

This is a 'quick and dirty' job that wouldn't look good or hold up for very long on the outside, but it's a lot more paint than was there from the factory in the engine compartment. I had a lot more trouble with dust today than usual, for some reason, but by the time everything is put back together, it should look fine.

Prepped:
http://img215.imageshack.us/img215/2477/img2231medium8zm.jpg

Painted:
http://img154.imageshack.us/img154/5365/img2240medium3sy.jpg

[Mr Project]

Here's a couple shots just for fun today:

The two cars in repose:
http://img215.imageshack.us/img215/1316/img2228medium5tv.jpg

I'm thinking I should keep this stance and have the first 'pre-runner' Touring ever. :)
http://img154.imageshack.us/img154/8465/img2243medium6hw.jpg

[323I Junkie]

teh 535XiT-Lifted

Did you get the long bolts out of the oil pan?

[gtopaul]

gtopaul:

how long have you had your touring. I owned an idential (albeit stock, other than wheels and suspension, but always thought of a S50 swap) cashmere beige 92 touring from 95-99 here in Ca. (not that it's a super rare car, but i often wonder what happened to it).
Mike

I purchased the car last summer for $3k. It came out of Indiana originally and because of that I have a few little spots of rust to take care of at some point.

I took the car on it's first road trip yesterday and back today, a total of 360 miles of interstate driving. Averaged 29mpg on cruise control at 80mph. That's about 5mpg better than the original engine combo so at least that $6k bill for the swap is having some dividends. The trip did point to a few problems that I need to fix though. I have a resonating noise like a loose heat shield at idle and there is a nasty vibration that comes and goes over 80mph which I'm about 100% sure is the original driveshaft. I had the same vibration, somewhat to a lesser degree, before the swap so I'm pretty sure it's the driveshaft. I replaced the quibo and checked the center bearing when I did the driveline swap. I just did some checking around and it seems reman driveshafts are available from a few different sources but it looks like the Touring uses a different part number than the sedan. I thought they were the same and wonder what the difference is. Probably will get relacement from Portland driveline service since they have a club discount and a very good reputation but if anyone has another source please give me a yell.

Mr project, wow, totally awesome paint work on the engine compartment! Are you going to detail the engine like that before the installation? If so I can't wait to see it. ;-)

Paul

[Mr Project]

7/7/06 update:

Well, the 3-day flurry has come to a close and I didn't get nearly as much done as I wanted to, but progress was made nonetheless.

1 - Painted engine compartment of Touring
2 - Stripped remaining 5-speed swap pieces from sedan
3 - Installed new timing chain, guides, tensioners, gaskets, and oil pan gasket on M30B35
http://img212.imageshack.us/img212/9455/img2246medium9fh.jpg
4 - Installed new clutch pivot ball, cleaned and lubed throwout bearing
5 - Cleaned up M30B35 for installation
http://img60.imageshack.us/img60/7979/img2248medium2ef.jpg
http://img212.imageshack.us/img212/7489/img2247medium5uj.jpg
6 - Ordered suspension (Koni/Eibach) for Touring + misc. small parts

Sadly, no, the engine won't be quite as clean and purdy as the engine compartment... but it's not too bad.

[HE53]

That is awesome. You have been working quite well and productive. :buttrock

[323I Junkie]

what happened with the oil pan?

[Mr Project]

I did get the long bolts out, but there were 2 bolts at the back of the pan, tucked up inside the webbing, that I missed. If you were on your back under the car you'd see them right away, but I didn't get far enough under the motor while it was hanging on the hoist and I missed them the first several times. Once I got them out it came right off.

[323I Junkie]

funny how that works!

IM rbuilt the b34 and Im doing the b35 this year just because I anticiape a few years that i wont have time to do much daily driver work, besides, Im getting a little more leakdown in it than anyone should for a b35 thats only at 158, but then again its been overheated pretty bad and driven hard its whole life, the PO maintained it well but the PO's liscence read "22 FAST" have no idea why

I just love taking that engine apart and putting it together..its a blast, such a great piece of engineering

[Mr Project]

Junkie, what do you use to tighten the crank pulley nut?

[brosher]

The best part about this project is that it is taking place in a driveway, not in some fancy shop. The cleaned up engine bay looks great. *drool*

I can imagine all the cussing and banging directed at the oil pan. Then the "doh" when you noticed the bolts. We've all been there...

[Mr Project]

Well, I don't know, my garage is pretty fancy. :P I do have internet access and a TV out there. Not that I spend most of my time in the garage or anything. :) I was in an electrician's warehouse the other day thinking....'imagine what I could build if I had this much room!'

I'm hoping that I can get the engine actually sitting in the Touring engine compartment this week. Time will tell.

[Dark Helmet]

nice man, nice...

[323I Junkie]

Junkie, what do you use to tighten the crank pulley nut?
flywheel holding tool and a big socket...i forget which size, ive got a 3/4 drive set

[BMRSEB]

Looking good, great work!!... Since you're painting and all, you should shadowline that baby too!! :cool

[Mr Project]

I might at some point...though on the darker colors I think I actually prefer the stainless trim.

[gtopaul]

Ok, I got my M5 front sway bar and it doesn't have the notch in it like the Touring bar. Decided to ebay it since I don't really want to cut the crossmember brackets off. Then while eating breakfast this morning the thought hits me that maybe the Touring bar is notched to clear the U-shaped trans brace that bolts to the crossmember and auto trans instead of the crossmember itself. Mr Project, did you notice when you pulled the bar off if that's the case or not? I won't be able to check until I get the car on a lift again.

I still haven't got my rear M5 sway bar yet. The parts guy screwed up my order and I received one front sway bar bushing, one rear sway bar bushing, and one rear sway bar link. Who in their right mind would order just one? Parts guys kill me sometimes.

Also, I ordered a reman driveshaft from Driveline Service of Portland and should have that early next week. That should cure my high speed vibration problem. Next thing to fix is the vibration/resonation "drone" that occurs at idle, in drive, when warmed up. Maybe I need to put that trans bracket back on. :eek:

Paul

http://members.aol.com/paul3130/private/ebay018.jpg

[Mr Project]

Paul, that's a good question. I'm not sure, I didn't notice when I pulled it out. I'll check for you, but unfortunately I won't have a chance to be under the car much, if at all, this week.

[Mr Project]

Not too much of an update. I've been busy with other stuff this week, and next week will actually be much worse...I'm working on other stuff every night.

I did get a little re-assembly work done in the engine compartment:

http://img230.imageshack.us/img230/4461/img2297mediumlk0.jpg


I also got the heater core in the Touring replaced:

http://img396.imageshack.us/img396/6770/img2260smallxo2.jpg
http://img468.imageshack.us/img468/5562/img2296mediumwg4.jpg

[Mr Project]

Here's what I think is probably the toughest part of the 5-speed swap so far: The bracket for the clutch return spring.

This is the AUTOMATIC bracket: (I have the clutch master cylinder hanging in this picture)
http://img366.imageshack.us/img366/3476/img2287mediumao1.jpg

This is the MANUAL bracket:
http://img230.imageshack.us/img230/809/img2288mediumlb8.jpg

Notice that the little side bracket for the clutch spring is not on the automatic bracket. This bracket would be very difficult to swap...it goes up and over the steering column...the entire column would have to be dropped, and one of the bolts is even the 'non-removable' type with no head. You'd have to be able to get in there and cut a groove in the head, which would not be an easy task.

I've been debating the best way to go about this...if I could get the old one cut off in place, welding it on would be no big deal. I don't have anything remotely like the right tools to get that cut off in it's current position, though. I'm not even sure what they would be.

So, I'm working on getting the bracket out of the parts car, cutting off the clutch spring support, and then finding a way to attach it to the Touring.

I thought about fabricating my own clutch spring support from bulk steel, but so far that's not looking real great. I might still end up going that route, though.

[Mr Project]

One more picture today: A teaser....I'm really excited about this part. I've never owned a car with a really good aftermarket suspension setup in good shape...once this is done I have the Corvair hot on it's heels with a fully rebuilt suspension as well. Doesn't make driving a 260k Volvo any easier right now, though. :)

http://img63.imageshack.us/img63/2908/img2302mediumzb8.jpg

[323I Junkie]

awseome...Christmas in July

[Mr Project]

Yeah right...except I never get anything this good for Christmas. :D

[Mr Project]

Well, Paul, it does appear that the M5 front bar will just fit with the automatic brackets.

In these shots, the bar is bolted up about 75% tight to the frame, and just slid over the endlinks with the endlink nuts threaded on about 2 turns.

It's not 'fully bolted' in, but the position shouldn't really change if it was tightened up. I think it would probably be ok, but if I was to go this route I'd just cut off the brackets for peace of mind.

http://img65.imageshack.us/img65/8099/img2315mediumcj2.jpg
http://img68.imageshack.us/img68/1627/img2318smalljc2.jpg

[Mr Project]

Just to add...you'd gain about another 1/4" by removing the bolt-out portions of the brackets as well. That might be enough to be pretty comfortable with the positioning.

[WebDev]

Project, project, project!

[323I Junkie]

Is there an easy way to make a website on this project?

[Mr Project]

I'd be open to suggestions on that front. I haven't come up with much so far because a) I don't have any meaningful hosting space available, and b) I don't like 'blog' formats for project documentation. Oh and c) I'm a cheapskate that isn't going to pay anything.

:D

[323I Junkie]

Im actually thinkinf of purchasing some server space. Id like to document many things on the TA project and other cars. Im not a cardomain guy, I just want a build a nice website for pictorial how to's on bmw's

[leif]

Why don't you just find a used manual pedal assembly. When I converted my 95 525i, the whole thing bolted in. That top bolt needed the head to be ground off and replaced with a new bolt.

[Mr Project]

Well, I have a perfectly good used pedal assembly already, it's just still in the car. :) I was hoping not to have to tear things down quite that much, but as Homer says: "You can't go this far and then not go farther!" :D :D

[WebDev]

Is there an easy way to make a website on this project?

That's an idea. A website that allows people to post projects in a readable format.

I do website programming btw. :devillook

[RVAE34]

I am getting ready to do a turbo setup on my car with an air to air intercooler, and a rebuild on the extra short block I have. I would be happy to take a million photos to document and submit to this website

[FLi GLi]

I have server space i'd be willing to donate to host a website for this project.

If someone wants to work with Mr. Project to put a simple page together (I would, but I just don't have the time) I am more than happy to host it.

Anyone? If someone is interested is doing the website development, feel free to email me at 1gli@cox.net.

FLi

PS - Mr. Project - How tough is the heatcore replacement? I recenetly purchased a 525I sedan 5spd for my girlfriend. In the winter, when the heat is on, it uses coolant and you can smell coolant in the cabin. I'm guessing a leaky heatercore. Thanks.

[LJSE34]

I could put it on bmw4life.com if you want. The site needs some new material anyway. Haven't updated in ages :( Oh well, we all get busy at times. I use simple formats so making a page is pretty easy and quick for me.

[WebDev]

I have server space i'd be willing to donate to host a website for this project.

If someone wants to work with Mr. Project to put a simple page together (I would, but I just don't have the time) I am more than happy to host it.

Anyone? If someone is interested is doing the website development, feel free to email me at 1gli@cox.net.

FLi


I'm actually more interested in the idea of creating a site that hosts projects. Where someone can lay out the details of their project in a logical and easy to read way, line items, descriptions, pictures.

[autophile]

I also have some hosting space and would like to be involved in a project like a web site to display how-to's.

WebDev, check your PMs

/hijack

[323I Junkie]

It would be great, like I will be doing the v12 project and "Hell Seven" project

[gtopaul]

Just to add...you'd gain about another 1/4" by removing the bolt-out portions of the brackets as well. That might be enough to be pretty comfortable with the positioning.

Thanks for the info! Looks like there might be enough room if I remove the brackets. I've got the sway bar on ebay but it ends this AM. I'll give it a shot if it doesn't sell. Still waiting for the rear bar to show up. Must be on the slow boat from europe. I did get the new driveshaft in and will probably do it and the rear sway bar at the same time.

Thanks!

Paul

[Mr Project]

Thanks to some good pointers on bimmer.info, I realized that just removing and swapping the steering column brackets was going to be the easiest way forward.

Unfortuantely I've only had about 2 hours to work on the car this whole week. Hopefully this next week will offer more opportunities to make some progress.

For the benefit of everyone else, here's the basic idea for steering column removal. I don't think this is covered in the Bentley, and I couldn't find much on-line.

Assuming you've removed everything in your way up to this point...lower dash, column plastic, pedals, etc. You can probably do this with the pedals installed, but I'm not sure what all complications that might add. You'll also need to remove the accellerator pedal linkage.

1 - Just remove 2 bolts "A" from the front end of the column.

2 - Pull down on the steering wheel hub. This will give you enough clearance to reach the 2 bolts "B" with a box-end wrench or maybe even a ratchet with a short socket.

3 - Disconnect all the wiring harness connectors and pull the assembly straight off. The big nut on the column should pull straight off the steering shaft that goes into the box.

4 - Bolt "C" is my replacement for the headless shear bolt that holds the pedal bracket to the steering column assembly. I tried welding a nut to it for removal, but it worked a lot better to cut a groove in the head and then use a hammer and a flat-blade screwdriver to spin it off. I used a low-grade metric M8X1.25 bolt to replace it.

http://img353.imageshack.us/img353/4919/img2350largegu4.jpg

[Mr Project]

Incidentally, if someone wanted to 'tilt' their E34 steering column down a little, a couple of washers on the top side of the "A" bolts would do the trick. There's quite a bit of 'flex' in the joints that lead to the steering shaft, so I imagine that wouldn't present any long-term issues as long as the movement was within reason.

And yes, if somebody would like to offer a little hosting space and some HTML assistance, I would LOVE to put this type of information in a web project database of some kind. I have a little basic HTML ability, but not much. I think it would be helpful for the E34 community, especially as these cars age and parts cars become more plentiful....5 speed swaps and the like may become more commonplace and the Bentley just doesn't offer much help in that regard.

[Mr Project]

Well, I've actually been working pretty hard on the project lately, but it's not very exciting progress. :)

You've all heard about suspension swaps before, and it's mostly that. I'll include some pics to keep this interesting.

First I cut down the stock 535i bump stops...the final product is around 3 inches long, and preserves the 'soft' end section, much like the (much more expensive) M5 bump stops.

http://img171.imageshack.us/img171/8404/img2367smallnh2.jpg

Then I assembled and installed the rear strut assemblies (Koni/Eibach) and the fronts:
http://img456.imageshack.us/img456/2530/img2376smallne4.jpg
http://img213.imageshack.us/img213/3784/img2389smallen7.jpg
http://img178.imageshack.us/img178/1152/img2388smallzd5.jpg

I also removed all the SLS components...just the hardlines running the length of the car and the rear ride height sensor remaining.
http://img178.imageshack.us/img178/420/img2379smallsv0.jpg

Finally, I also swapped over the entire front subframe from my sedan parts car. It's got some relatively new steering parts, newish thrust arms, and better control arms, so rather than replacing everything again on the Touring, I swapped over the OK stuff from the sedan. If I can get a year or two out of this stuff before having to rebuild the front suspension again, I'll be happy.

[Mr Project]

As of tonight, I also learned something else interesting.

For some reason I was thinking that the stock diff in the Touring was a lower gear ratio than 3.46:1. However, cleaning up the diff a little revealed 4 interesting characters: S, 4, 1 and 0, in that order. It's a limited-slip 4:10 rear.

Is anybody else curious what an M30B35 wagon would feel like with a 5-speed and a 4:10 rear? I know I am. :D :D :D :D :D

If I can't stand it, which I think I won't be able to for very long, I'll swap the 3:46 in and go back to the stock combination. I've found that I can swap the diff in a shockingly small amount of time.

[HE53]

As of tonight, I also learned something else interesting.

For some reason I was thinking that the stock diff in the Touring was a lower gear ratio than 3.46:1. However, cleaning up the diff a little revealed 4 interesting characters: S, 4, 1 and 0, in that order. It's a limited-slip 4:10 rear.

Is anybody else curious what an M30B35 wagon would feel like with a 5-speed and a 4:10 rear? I know I am. :D :D :D :D :D

If I can't stand it, which I think I won't be able to for very long, I'll swap the 3:46 in and go back to the stock combination. I've found that I can swap the diff in a shockingly small amount of time.
I'd like to know.. Thats the same diff I have in my auto car. I need to pick up a 3.46 for my manual though..

I've got a 3.91 thats not being used.. Maybe I should throw it in there..

[Mr Project]

Yeah, there are a few guys on bimmer.info that run 3.91s with the Getrag 5-speeds. Frankly I think 3.91 would be the absolute limit of what I could stand long term...the 3.46 already spins over 3k at 80MPH

[project3]

i have learned soo much jus reading this thread:redspot. i love this forum.:buttrock:buttrock

[Dark Helmet]

As of tonight, I also learned something else interesting.

For some reason I was thinking that the stock diff in the Touring was a lower gear ratio than 3.46:1. However, cleaning up the diff a little revealed 4 interesting characters: S, 4, 1 and 0, in that order. It's a limited-slip 4:10 rear.

Is anybody else curious what an M30B35 wagon would feel like with a 5-speed and a 4:10 rear? I know I am. :D :D :D :D :D

If I can't stand it, which I think I won't be able to for very long, I'll swap the 3:46 in and go back to the stock combination. I've found that I can swap the diff in a shockingly small amount of time.



:eek: :eek: :eek: :eek: :eek: :eek:


i can't sit still over here... holy crap... can we PLEASE Bolt that into the E28 and run the 1/8th with it.... PLEASE!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

I sooooooooooooo want to immolate tire.... oh man, I'm litterally bouncing here... holy moly... wow, just wow....




heeehehhehehehehehehehheheheheeeeeeee:evil2

[Dark Helmet]

you'll drop a few RPM with the slightly oversized tires from the E60...


I can't waut to see those OE touring wheels on the 'vair though... that will be cool....

[shragon]

kick ass thread!

[Mr Project]

i can't sit still over here... holy crap... can we PLEASE Bolt that into the E28 and run the 1/8th with it.... PLEASE!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

I sooooooooooooo want to immolate tire.... oh man, I'm litterally bouncing here... holy moly... wow, just wow....


No, I'm not passing the diff around to be the High Street Bicycle. Plus that's an extra 2 or 3 hours of work that I could spend cleaning carpets.... :(

[Dark Helmet]

hey, I can actually do the diff alone... assuming I don't destroy another sway-bar mount...

[Dark Helmet]

also, did you ever post pics of your pimpin flywheel?

[Mr Project]

No, I should do that when I get back.

And no, I don't want to derail the project schedule, such as it is, to take an E28 break so you can giggle and spin tires. I'm going to be busy doing that myself. :)

[Dark Helmet]

gah! foiled again!

[LJSE34]

kick ass thread!

Not to jack the thread. I like those new tail lights! Looks much better imo.

[Dark Helmet]

dude, no jacking!!!!! :D:D:D

[Rob Levinson]

Yeah, there are a few guys on bimmer.info that run 3.91s with the Getrag 5-speeds. Frankly I think 3.91 would be the absolute limit of what I could stand long term...the 3.46 already spins over 3k at 80MPH

'91 US M5s are configured with the 3.91 and the 5-speed Getrag 280 has the same ratios as the Getrag 265. It really is quite livable, never seemed out of the ordinary to me.

Take a look at how the speed in gears works out... this page shows 5-speed/3.73, 5-speed/3.91, and also various 6-speed (different ratio) configurations:

http://www.robertlevinson.com/M5_Touring/upgrades/transmission.htm

- Rob

[Dark Helmet]

Rob, that 4.10 makes interstate cruising a 3650rpm ordeal... that's steep... and that's only at 80...

not even 100mi west of here "normal" is 85, and that means a steeeeeeeeeeeep 3875rpm or so...

that will NOT be fuel miserly, by any stretch...

the 3.91 would be OK, but the 3.46/3.64/3.73 range is more appropriate.

back east, speed limits are lower and average speeds seem a bit lower as well... out here, its either stop and go in town, or 75-85 on the interstates and highways.

[Dark Helmet]

ideal for this car is actually about 14psi and a 2.97 large-case from a 750.... but I believe that would require replacing a bunch more parts.

[Mr Project]

Rob, my 'can't stand' issue with a higher rear gear is primarily fuel economy and powerband...there's just no reason IMO to spin a daily-driver M30 to nearly 4krpm on the interstate. An M5 is a whole different proposion, that S38 powerband is a little different, and frankly if I was driving an E34 M5, fuel economy wouldn't be a concern. :D

[Dark Helmet]

indeed.

[323I Junkie]

Any of you guys ever driven a manual tranmission m3028 or m30-30?

[Dark Helmet]

no... a guy armen used to work with (dude retired), has a grey-market E12 M535i though.... it looks like it did when it rolled off the line too... and he drives it every day... its amazing.

[RVAE34]

pics would be excellent... I saw the most beautiful 88 E28 yesterday. 535i amazing pearl grey paint job. Killer euro kit with light washers, lowered, 17" BBS wheels. black leather 5 speed. I pulled the guy over and got his number. I hope to get some pics to share. It was unbelievable and made me really want an E28 M5. I think that will be next for me. After I turbo charge the E34

[Dark Helmet]

well kept E28s are amazing...

mine on the other hand... eh, well...

[323I Junkie]

I may get one...

[Dark Helmet]

want mine???

[323I Junkie]

no, selling everything, everything right now
except Smokes

[Dark Helmet]

and the L7...

[323I Junkie]

Sadly, probably that too.Everything. Already gave away the 323 to my friend.

I just...I dont know whats happened. I just dont seem to have any time whatsoever anymore to work on anything. I am so damn busy. Sad because thats what makes me happy. But I ran the numbers and if Im ever going to get anything done, I need to sell it all. I also need a car that fits my lifestyle. IM always hauling this or that, driving 100 miles or so., going to the mountains, picking up this, taking mountain bikes, all that. X5 3.0 just seems like the better vehicle. Turn the key and just f'n go. I just rebuilt, compeltely, the L7's underhood. The engine, all hoses, pumps, injectors, EVERYTHING wearable was replaced. Even new coolant temp sensors everything.
Whoever buys that, if I can actually bear to sell it, is getting quite the deal. I love that car, but damn...it still needs new fupholstery, paint, and new \"stuffing" in the front seats. Needs complete suspension..sadly, even with all of that..she still is a very, very stately beauty! The car with turbos and a 5 speed could be so, so badass...but..
Turbos..$6000
Paint..$6000
Upholstery..$2000
Transmission...$2000
Suspension...$1000

I guess 17K isnt that much compared to 30 for an X5...but, I have month or so to brood about it. The seven has never, ever, ever, left me ont he side of the road. Shes always got me home..seems unloyal somehow

the 535 I just have bad karma with, no other way to describe it

The subruban costs 125 dollars a week in fuel to operate..

[Mr Project]

Quick update: I've been out of town this week, but I got a few things done today:

1 - Cleaned up and re-installed 4:10 diff.
2 - New fuel filter.
3 - Installed 19mm rear M5T sway bar.
4 - Installed new backup light switch and OEM short shifter with new bushings.
5 - Finished installing clutch pedal and return spring. Adjusted brake pedal for height.

Check out the new flywheel...can you guess which is the new 18lb lightened M30B34 flywheel, and which is the old 32lb dual-mass? :) I think with this and the temporary 4:10s it's going to be something of a hot rod. :D
http://img205.imageshack.us/img205/6041/img2431mediumvk8.jpg
http://img75.imageshack.us/img75/9641/img2429mediumcp5.jpg

[uberkarldrei]

totaled (late brake, late turn in, 4 broken wheels and a bent car) my e28 with a euro M88/3 motor in it and decided to put it into an e34. ( the twisted swaybay hurt the most )
couldn't find a touring but did pick up a early (m20) 525i e34 cheap

any extra words of wisdom on the installation / modification of the clutch pedal assy.

luckily I do have a machine shop and welding equipment at my disposal, so fabbing up my own parts aint bad but time consuming.

still leaving the 525i badge on and getting the "baby on board "and "I stop for all garage sales" bumperstickers on the back to keep a low profile. still havent figured out how to hide the 3" exhaust yet

[RecklessKelly]

Check your pedal assy first. My '89 m20 has the clutch return spring perch on it already. Good luck with the conversion.

[Mr Project]

Yeah, a lot of the earlier E34s have the same pedal box for auto or manual. You might already have the perch for the clutch return spring. If you do, it's just a matter of getting your hands on:

Clutch and brake pedals
Long bolt for 3-pedal pivot vs. current 2-pedal pivot
Bushings and metal spacer for clutch pedal
Clutch return spring assy.
Clutch stop
Small bracket and switch for clutch sensor that kicks off cruise control when clutch depressed.
Clutch master cylinder and 2 rubber boots for holes that go through firewall.

That's just in the immediate pedal area. You'd obviously still need all the other stuff like the hard and soft lines for the clutch hydraulics, and the shifter and driveshaft related stuff. There's also the question of the wiring for the clutch switch, but I haven't really looked at that yet to see if the wiring is already there and just tucked away on the automatic car.

Your biggest challenge will probably be the engine mounts and the engine-related wiring for the M88. The E28 engines don't mount the same way and the E34 ECUs are set up to be in the engine compartment rather than the glovebox, plus the big diagnostic-type connector will probably be different where the engine harness mates to the body harness.

[Mblaster]

Great thread Mr Project:buttrock

[russelcq]

The M88 wiring harness will be very long on the main harness to the ECU. Not sure where the extra length will fit.

RussC

[323I Junkie]

perfect time to go MS and use the coilpacks off of an m50

[Dark Helmet]

indeed.

armen didn't get much done tonight as he was helping me get my new baby running.... sorry guys.

his drop-dead date is October 1. we WILL have it finished by then.

[Dark Helmet]

btw, armen... I was thinking you me and Jeff need to spend a day wrenching on it to really get the kinks worked out.

[Dark Helmet]

we need before/after pics of the carpet man... lets see it!!!!

[Dark Helmet]

bump for pics.... come on man!!!!

[Mr Project]

Well, I thought I had a 'before' picture, but I guess I don't. You'll have to take my word for it that it looked like 2 or 3 people had been murdered and then transported in the back of this car 5 years ago. It was disgusting....filthy and stained beyond belief.

After literally 3 rounds of carpet cleaning, and then 3 rounds of steam cleaning, here's the cargo area panels. I had them all out to do the rear suspension install, so I got them all put back in last night.

http://img213.imageshack.us/img213/135/img2486mediumqx4.jpg

I also got the A/C evap. cleaned up and hopefully will be able to re-assemble the lower dash area where I replaced the heater core.

[Dark Helmet]

very nice...

October 5... remember, October 5.

[FLi GLi]

I also got the A/C evap. cleaned up and hopefully will be able to re-assemble the lower dash area where I replaced the heater core.

Mr. Project-o,

How hard is doing the heater core if you aren't doing an engine swap and otherwise tearing the car apart? Any tips? I think I may have to do this in the near future.

Great thread, BTW. Enjoying it immensely. Good luck!!

FLi :cool

[Mr Project]

So what kind of GLi do you have? I thought about picking up a '92 a while back...kinda neat cars. :) Your location is cool, too...my sedan parts car originally came from Leesburg, VA.

Honestly there are a lot of horror stories about the heater core but I didn't think it was too bad. I followed the Bentley version of the instructions and it's doable without removing the dash top. Removing the aluminum pipes that feed into the core, though, that's another story. I fiddled around with those for a while and then decided I was better off re-using them with new O-rings. I honestly have no idea how you'd get those out without SERIOUSLY tearing down the heater box, which would require a lot more dissasembly.

Different year E34s apparently have different heater core/heater pipe arrangements, too, so your mileage may vary. Mine was for the '92, I haven't gotten the '91 torn down enough to see what the differences might be on that year.

[FLi GLi]

So what kind of GLi do you have? I thought about picking up a '92 a while back...kinda neat cars. :)

I have a '90 GLi, Mk2. I believe the kids these days are calling that "old skool" :D . It was my first "performance" car (has the 2.0l 16V engine) and still holds a special place in my heart (and garage) even though I've graduated up the performance ladder, so to speak. I learned alot about wrenching on that car. She doesn't get the attention these days that she should :( . You can see pics of her here - http://cars.dcgoat.com/VWJettaGLi16valve/index.html


Your location is cool, too...my sedan parts car originally came from Leesburg, VA.

I'm about 25 minutes Southeast of Leesburg in the Herndon/Reston area.


Different year E34s apparently have different heater core/heater pipe arrangements, too, so your mileage may vary. Mine was for the '92, I haven't gotten the '91 torn down enough to see what the differences might be on that year.

Thanks for the info on the heater core. Sounds like I need to pickup a Bentley before tackling this job. My 525i is a '91, so I'd be interested in your opinion on how difficult it is once you do that one.

In the winter when using the heat, I'm going through coolant and noticing a coolant smell in the cabin, which is why I think the heatercore is leaking/bad. Since I stopped using the heat and started using the A/C for the summer, coolant level has not moved one bit and no smell in the cabin. Therefore, I think my diagnosis is pretty sound.

Keep up the great work on the conversion! I am living vicariously through you as I've always wanted an E34 Touring.

FLi :redspot