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Thread: Build Thread: 1991 325ic Restoration + engine swap

  1. #26
    Join Date
    Oct 2009
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    Buford, GA
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    I'm running an AEM Failsafe and like it a lot
    E30 325iC turbo convertible project in progress (updated 12/23/15):
    Car fully tuned on completely rebuilt M20 w/forged internals, MLS head gasket
    Suspension, brakes, exhaust fully installed
    New carpet, custom reupholstered seats installed, door panels painted to match
    Custom center console gauge panel installed
    Plastic bumper conversion complete, MTech2 front spoiler installed
    Rear bumper conversion in progress
    Build thread: http://forums.bimmerforums.com/forum...on-engine-swap

  2. #27
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    Oct 2009
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    Currently disassembling spare engine block. Hope to take it to Wills Machine Shop near Atlanta for cleaning, inspection, & prep.

    Next steps:
    1) Have machine shop clean/inspect/measure block & crank, machine surfaces
    2) Order bearings, pistons, & rings (sizes dependent on block/crank tolerances)
    3) Have machine shop install rotating mass
    4) Order Bimmerheads performance M20 cylinder head
    5) Begin reassembly of M20 long block with new hardware, hoses, reman accessories (AC compressor, PS pump, alternator
    6) Order & install suspension rebuild kit & shock/spring kit (either Bilstein Sport + H&Rs or Touring Cup - want sporty corners + comfort)

    May be looking for new or like-new M20 engine wiring harness. Let me know if you know of one!!
    Last edited by E34DIYer; 04-07-2014 at 06:42 PM.
    E30 325iC turbo convertible project in progress (updated 12/23/15):
    Car fully tuned on completely rebuilt M20 w/forged internals, MLS head gasket
    Suspension, brakes, exhaust fully installed
    New carpet, custom reupholstered seats installed, door panels painted to match
    Custom center console gauge panel installed
    Plastic bumper conversion complete, MTech2 front spoiler installed
    Rear bumper conversion in progress
    Build thread: http://forums.bimmerforums.com/forum...on-engine-swap

  3. #28
    Join Date
    Oct 2009
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    She's not much to look at now, but give us a few months!

    E30 325iC turbo convertible project in progress (updated 12/23/15):
    Car fully tuned on completely rebuilt M20 w/forged internals, MLS head gasket
    Suspension, brakes, exhaust fully installed
    New carpet, custom reupholstered seats installed, door panels painted to match
    Custom center console gauge panel installed
    Plastic bumper conversion complete, MTech2 front spoiler installed
    Rear bumper conversion in progress
    Build thread: http://forums.bimmerforums.com/forum...on-engine-swap

  4. #29
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    Oct 2009
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    Project updates:

    Ordered a gallon of adhesive for the new convertible top, waiting for it to arrive.

    Dropped off the block at Brad's Automotive Machine shop in Gainesville for cleaning, hone, tolerance check, crank magnaflux, journal polish, and new freeze plugs. Unsurprisingly, cylinder and crank journal measured well within factory specs, so no turning or boring necessary. Putting together the money now for the pistons, rods, and bearings.

    We're probably going with Wiseco forged dished pistons and Eagle forged rods, unless someone can point me to a better product at a similar price point. We're also going with coated rod/main bearings, ARP hardware, and a Cometic MLS head gasket.

    I also purchased a parts washer and started monkeying with it. I ended up using PSC1000 parts solvent from Tractor Supply Company as my cleaning fluid, as it doesn't reek like kerosene and is safe for aluminum (unlike Purple Power).



    Lastly, we pulled the project car's engine so it can live on in another enthusiast's car:
    E30 325iC turbo convertible project in progress (updated 12/23/15):
    Car fully tuned on completely rebuilt M20 w/forged internals, MLS head gasket
    Suspension, brakes, exhaust fully installed
    New carpet, custom reupholstered seats installed, door panels painted to match
    Custom center console gauge panel installed
    Plastic bumper conversion complete, MTech2 front spoiler installed
    Rear bumper conversion in progress
    Build thread: http://forums.bimmerforums.com/forum...on-engine-swap

  5. #30
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    Oct 2009
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    Anyone know of a comprehensive guide to rebuilding an M20 - something with recommended sequences and/or clearances for bottom end internals?
    E30 325iC turbo convertible project in progress (updated 12/23/15):
    Car fully tuned on completely rebuilt M20 w/forged internals, MLS head gasket
    Suspension, brakes, exhaust fully installed
    New carpet, custom reupholstered seats installed, door panels painted to match
    Custom center console gauge panel installed
    Plastic bumper conversion complete, MTech2 front spoiler installed
    Rear bumper conversion in progress
    Build thread: http://forums.bimmerforums.com/forum...on-engine-swap

  6. #31
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    Oct 2009
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    Hmm, no one's interested in this thread. Oh well, for my own notes..

    Sourced the internals for the engine and got a great price. Here's what I'm going with:
    - Wiseco dished forged pistons
    - Eagle 135mm rods
    - Cometic MLS head gasket (.070)
    - ARP head studs
    - ARP main studs
    - ARP rod bolts
    - ACL race main/rod bearings
    Total price: $2155 shipped.

    Block's still in the machine shop. They're hot tanking the block, so they'll be replacing the intermediate shaft bearings for me.
    E30 325iC turbo convertible project in progress (updated 12/23/15):
    Car fully tuned on completely rebuilt M20 w/forged internals, MLS head gasket
    Suspension, brakes, exhaust fully installed
    New carpet, custom reupholstered seats installed, door panels painted to match
    Custom center console gauge panel installed
    Plastic bumper conversion complete, MTech2 front spoiler installed
    Rear bumper conversion in progress
    Build thread: http://forums.bimmerforums.com/forum...on-engine-swap

  7. #32
    Join Date
    Jun 2005
    Location
    Oregon
    Posts
    204
    My Cars
    89 325i Vert, 90 Corvette Vert
    I've been keeping up with it. I'm guessing no one knows of the guide you were asking about. Your best bet if you don't have one already is to get a Bentley manual.

    Best of luck with it.
    e30 Vert project

    "The two loudest sounds a gun owner hears is a bang when he expects a click and a click when he expects a bang"

    Recently heard - "The shear number of people who have made me wish there was a hell for them to rot in has forced me to re-examine my atheist beliefs."

  8. #33
    Join Date
    Apr 2009
    Location
    Plant City, Florida
    Posts
    254
    My Cars
    89 325ic; '16 WRX
    I just recently rebuilt my motor and I used the Bently and Hyanes manuals together. If you have any question just ask and we will try to answer them.
    My e30 vert build http://forums.bimmerforums.com/forum....php?t=1899641

    Nothing But Bass: E30 Bass
    I have money, I just want to use yours.

  9. #34
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    I wasn't there to see the shortblock disassembled, but I'm assuming it's similar to other engines...

    1.Reinstall the oil pump
    2.Insert pistons w/lightly oiled rings & connecting rods
    3.Place upper half of crank bearing into block, lightly oil w/assembly lube
    4.Place crankshaft onto block/ bearings
    5.Install ARP main studs
    6.Place lower half of crank bearings into main caps & lightly oil
    7.Attach main caps to block, using plastigage to check bearing clearance
    8.Attach connecting rod caps to rods w/bearings, using plastigage to check clearance
    9.Install crankshaft front & rear main seals

    ...?
    E30 325iC turbo convertible project in progress (updated 12/23/15):
    Car fully tuned on completely rebuilt M20 w/forged internals, MLS head gasket
    Suspension, brakes, exhaust fully installed
    New carpet, custom reupholstered seats installed, door panels painted to match
    Custom center console gauge panel installed
    Plastic bumper conversion complete, MTech2 front spoiler installed
    Rear bumper conversion in progress
    Build thread: http://forums.bimmerforums.com/forum...on-engine-swap

  10. #35
    Join Date
    Apr 2009
    Location
    Plant City, Florida
    Posts
    254
    My Cars
    89 325ic; '16 WRX
    That's it. Oil pump will be the last thing you install before the oil pan. I found it easier to get the crank installed and torqued down before installing the pistons. And yes plastiguage to check the main bearings and rod bearings. For the purpose of oiling the bearings and rings I used STP oil treatment, it has the consistency of honey and will leave a thicker layer film until you get the motor started.
    My e30 vert build http://forums.bimmerforums.com/forum....php?t=1899641

    Nothing But Bass: E30 Bass
    I have money, I just want to use yours.

  11. #36
    Join Date
    Dec 2007
    Location
    Vancouver, WA
    Posts
    420
    My Cars
    97 BMW 328i
    I think people like to see more pictures. I'm interested tho, sorry don't know the clearances your asking for.

    1985 BMW 635csi || Auto || 200k || 15" Borbet || Delphin

  12. #37
    Join Date
    Jul 2011
    Location
    Mechanicsville MD
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    50
    My Cars
    1985, 323i TC Baur
    The following link has a basic check off list for an M20 assembly that's off the e30tech website. Has a lot of torque specs which I found useful. The bentley is a good resource for bottom end clearance specs.

    http://www.e30tech.com/forum/attachm...8&d=1387466339

  13. #38
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    That was what I was looking for!! Thanks. Pics coming as soon as I have a block to take pics of....
    E30 325iC turbo convertible project in progress (updated 12/23/15):
    Car fully tuned on completely rebuilt M20 w/forged internals, MLS head gasket
    Suspension, brakes, exhaust fully installed
    New carpet, custom reupholstered seats installed, door panels painted to match
    Custom center console gauge panel installed
    Plastic bumper conversion complete, MTech2 front spoiler installed
    Rear bumper conversion in progress
    Build thread: http://forums.bimmerforums.com/forum...on-engine-swap

  14. #39
    Join Date
    Jun 2005
    Location
    Oregon
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    204
    My Cars
    89 325i Vert, 90 Corvette Vert
    Quote Originally Posted by csifan99 View Post
    That's it. Oil pump will be the last thing you install before the oil pan. I found it easier to get the crank installed and torqued down before installing the pistons. And yes plastiguage to check the main bearings and rod bearings. For the purpose of oiling the bearings and rings I used STP oil treatment, it has the consistency of honey and will leave a thicker layer film until you get the motor started.
    Used to do this as well. Other thing we'd do was to take an old distributor and modify it so we could attach a drill and pre-oil everything prior to initial start up.

    I'd imagine you could do the same one way or another with the m20
    e30 Vert project

    "The two loudest sounds a gun owner hears is a bang when he expects a click and a click when he expects a bang"

    Recently heard - "The shear number of people who have made me wish there was a hell for them to rot in has forced me to re-examine my atheist beliefs."

  15. #40
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    Thanks for the info. We're also looking ahead to Megasquirt, coil-on-plug (or coil packs), and electric conversions for the power steering, cooling fan, and maybe even the water pump.

    - - - Updated - - -

    Anybody ever put one of these on an E30, I wonder? http://www.unisteer.com/electric-power-steering/universal-electra-steer.html

    - - - Updated - - -

    Engine internals ordered.
    E30 325iC turbo convertible project in progress (updated 12/23/15):
    Car fully tuned on completely rebuilt M20 w/forged internals, MLS head gasket
    Suspension, brakes, exhaust fully installed
    New carpet, custom reupholstered seats installed, door panels painted to match
    Custom center console gauge panel installed
    Plastic bumper conversion complete, MTech2 front spoiler installed
    Rear bumper conversion in progress
    Build thread: http://forums.bimmerforums.com/forum...on-engine-swap

  16. #41
    Join Date
    Jun 2005
    Location
    Oregon
    Posts
    204
    My Cars
    89 325i Vert, 90 Corvette Vert
    Quote Originally Posted by E34DIYer View Post
    Thanks for the info. We're also looking ahead to Megasquirt, coil-on-plug (or coil packs), and electric conversions for the power steering, cooling fan, and maybe even the water pump.

    - - - Updated - - -

    Anybody ever put one of these on an E30, I wonder? http://www.unisteer.com/electric-pow...tra-steer.html

    - - - Updated - - -

    Engine internals ordered.
    $850, seems like some pretty expensive HP to me. What would the gain be? My understanding is that most modern power steering systems have a bypass valve for when the assist isn't needed so parasitic losses are pretty minimal.
    e30 Vert project

    "The two loudest sounds a gun owner hears is a bang when he expects a click and a click when he expects a bang"

    Recently heard - "The shear number of people who have made me wish there was a hell for them to rot in has forced me to re-examine my atheist beliefs."

  17. #42
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    More looks/cool-factor than HP concerns. :-) We'd like to clean up the engine bay as much as possible
    E30 325iC turbo convertible project in progress (updated 12/23/15):
    Car fully tuned on completely rebuilt M20 w/forged internals, MLS head gasket
    Suspension, brakes, exhaust fully installed
    New carpet, custom reupholstered seats installed, door panels painted to match
    Custom center console gauge panel installed
    Plastic bumper conversion complete, MTech2 front spoiler installed
    Rear bumper conversion in progress
    Build thread: http://forums.bimmerforums.com/forum...on-engine-swap

  18. #43
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    Oct 2009
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    Buford, GA
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    Updated post #1 with parts, part numbers, prices, and sources. Hopefully others can benefit from it.
    E30 325iC turbo convertible project in progress (updated 12/23/15):
    Car fully tuned on completely rebuilt M20 w/forged internals, MLS head gasket
    Suspension, brakes, exhaust fully installed
    New carpet, custom reupholstered seats installed, door panels painted to match
    Custom center console gauge panel installed
    Plastic bumper conversion complete, MTech2 front spoiler installed
    Rear bumper conversion in progress
    Build thread: http://forums.bimmerforums.com/forum...on-engine-swap

  19. #44
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    Got the shell stripped down. Carpet looked pretty nasty:



    Worse, there was some rust in the floorboards where old coolant probably pooled. We'll be having some fun with an angle grinder, epoxy, and aluminum plating later to fix this.






    But on the bright side, we got started on degreasing the engine bay, including installing the Condor Speed power steering delete block:







    E30 325iC turbo convertible project in progress (updated 12/23/15):
    Car fully tuned on completely rebuilt M20 w/forged internals, MLS head gasket
    Suspension, brakes, exhaust fully installed
    New carpet, custom reupholstered seats installed, door panels painted to match
    Custom center console gauge panel installed
    Plastic bumper conversion complete, MTech2 front spoiler installed
    Rear bumper conversion in progress
    Build thread: http://forums.bimmerforums.com/forum...on-engine-swap

  20. #45
    Join Date
    Jun 2010
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    Reykjavik Iceland
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    ALPINA B10 BITURBO
    Driving an E30 cabriolet is a fantastic feeling
    Sveinbjörn Hrafnsson

    E30 CABRIO V12 M70B50 ///
    ALPINA B10 BITURBO 346 @ 507
    ULTIMA Evolution
    Contacts
    http://alpina.123.is/pictures/

  21. #46
    Join Date
    Apr 2009
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    norcal
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    a few e30s
    Quote Originally Posted by B10 BITURBO View Post
    Driving an E30 cabriolet is a fantastic feeling
    Driving yours must be exhilarating.

  22. #47
    Join Date
    Sep 2008
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    Roseville, CA
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    89 325i, 91 318ic
    Nice work so far. I will admit that there are so many threads with "wish lists" or some kid dreaming of supercharging/turboing his motor, with absolutely no way of financing such a project, that I really don't pay attention until some actual work starts to begin. Now that you have shown some progress I will definitely be following along.

    I'm with Brad that the Autotopsdirect top that I purchased was an excellent choice. Quality construction and good materials. However, unless you have attempted this before, I would recommend having a shop do it. Or at the very least, watch them install a top on another car. It was a pretty involved process and was difficult to get right. You don't want to mess up a top you just paid $750 for.
    Sean

    A Company that will go to the ends of the Earth for it's people...will find that they can generally pay them 1/10th of an American worker.


  23. #48
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    We're thinking about the professional install, yes. Both for fitment and hassle reasons. Will keep updated!
    E30 325iC turbo convertible project in progress (updated 12/23/15):
    Car fully tuned on completely rebuilt M20 w/forged internals, MLS head gasket
    Suspension, brakes, exhaust fully installed
    New carpet, custom reupholstered seats installed, door panels painted to match
    Custom center console gauge panel installed
    Plastic bumper conversion complete, MTech2 front spoiler installed
    Rear bumper conversion in progress
    Build thread: http://forums.bimmerforums.com/forum...on-engine-swap

  24. #49
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    ALPINA B10 BITURBO
    Quote Originally Posted by dohcdoh View Post
    Driving yours must be exhilarating.
    OT

    i hope so,, v12 gives a great punch.. it should do

    with the S38B38,, it was really really quick......
    Sveinbjörn Hrafnsson

    E30 CABRIO V12 M70B50 ///
    ALPINA B10 BITURBO 346 @ 507
    ULTIMA Evolution
    Contacts
    http://alpina.123.is/pictures/

  25. #50
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    ARP head studs showed up from Modern Auto Performance. Waiting on Wiseco pistons from Modern Auto, also custom main studs from Top End Racing.




    Got the block back from the shop. Work done:

    Block hot tanked (shaft bearings removed beforehand)
    Crank magnafluxed, mic'd, and micropolished
    Cylinders mic'd and honed
    Freeze plugs replaced
    Head surface resurfaced
    Flywheel sandblasted & surfaced

    Total bill: $288... pretty typical as I understand it.

    Pics:











    Last edited by E34DIYer; 04-28-2014 at 11:03 PM.
    E30 325iC turbo convertible project in progress (updated 12/23/15):
    Car fully tuned on completely rebuilt M20 w/forged internals, MLS head gasket
    Suspension, brakes, exhaust fully installed
    New carpet, custom reupholstered seats installed, door panels painted to match
    Custom center console gauge panel installed
    Plastic bumper conversion complete, MTech2 front spoiler installed
    Rear bumper conversion in progress
    Build thread: http://forums.bimmerforums.com/forum...on-engine-swap

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