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Thread: S38B38 into my 1977 e12 chassis'd 633CSi

  1. #501
    Join Date
    Feb 2009
    Location
    Pittsburgh, PA
    Posts
    1,685
    My Cars
    '86 635CSi
    Quite the odyssey! The car has made some incredible progress over the years!

    I was outraged about that insurance subframe "repair" fiasco just from reading it. Despite the fraud they used to fleece & victimize, Aussie inspections appear to be somewhat more comprehensive to our slapdash American versions. Good thing you caught that and had it repaired properly. Although undoubtedly inconvenient & expensive, at the end of the day it only hurts in your wallet. The consequences would have been far more severe if that subframe sorted itself out!

    Thanks for keeping us updated too, it's a treat to follow along!
    Save the manuals!
    '08 128i 6MT, '96 318iS 5MT, '86 635CSi 5MT (B32, Motronic 1.3, WBO2, G265, 18# FW, 3.46 torsen)
    Past projects:
    '90 535iM, sold 1/23 '90 535iA sold 6/22 '91 318i, sold 7/19 '97 M3 sedan, sold 11/18 '85 735i, RIP 2/18 '92 325iC, sold 7/16 '91 318iS, sold 6/16 '84 745i, sold 10/14 '82 633CSi, traded 9/12 '90 325i, RIP '87 325 sold '89 525i, traded '87 325iS, RIP

  2. #502
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,446
    My Cars
    1x633, 1x E3 2 DR Racer
    Thanks Dave.

    The insurers eventually paid for the repair of the repair, after I got the new front subframe and proved the old one was bent. But I had to pay for it first. Not a good look when you client get's a bent car back and needs to repair it himself after you've found some b'ship excuse.

    Hopefully mid December we'll finish the shop tune and road auto-tune prior to hitting the dyno, more than likely early next year.
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 430hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  3. #503
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,446
    My Cars
    1x633, 1x E3 2 DR Racer
    Things are hopefully about to get underway again, post the Xmas break. Note that;

    1. Expecting ECU guru this Saturday morning to restart the ECU tune. Prior to the accident the car seemed to be running well. Now, 2 years on, the tune is for some reason all over the place, running rich at an AFR of 10:1. We need to pull fuel out so as to achieve an AFR of around 14:1.

    2. We'll drain the fuel tank and put in new fresh fuel plus clean the spark plugs, that have fouled given the rich running. We don't want to replace the spark plugs each time this happens as at $35 each, that adds up. $420 a swap, so a clean it is.

    3. Big brakes ordered and deposit paid. Going Willwood 6 piston front and back with AP Racing Rotars (323x32). Some old examples in the photos (used for test fitting).

    315529470_1268501900657861_3167207403912011898_n.jpg

    315531366_704536197495383_2343466544030331471_n.jpg
    Last edited by Shipper; 02-13-2023 at 10:41 PM.
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 430hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  4. #504
    Join Date
    Sep 2005
    Location
    North Carolina
    Posts
    10,537
    My Cars
    '86 M635/'10 Clubman
    Quote Originally Posted by Shipper View Post
    plus clean the spark plugs, that have fouled given the rich running. We don't want to replace the spark plugs each time this happens as at $35 each, that adds up. $420 a swap, so a clean it is.
    Are you using something like this?


    https://sunextools.com/products/spark-plug-cleaner/

    I like the concept in general, but boy I don't like the idea that any of the blast media persists and makes its way into my motor...

  5. #505
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,446
    My Cars
    1x633, 1x E3 2 DR Racer
    I'd assume so. There's a tonne on ebay for $40. They all seem to use an abrasive powder. Hopefully it works well.
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 430hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  6. #506
    Join Date
    Sep 2005
    Location
    North Carolina
    Posts
    10,537
    My Cars
    '86 M635/'10 Clubman
    Quote Originally Posted by Shipper View Post
    I'd assume so. There's a tonne on ebay for $40. They all seem to use an abrasive powder. Hopefully it works well.
    My understanding is they work very well. Just clean the ever-loving crap out of them to get rid of any of the abrasive media before you put them in the motor...

  7. #507
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,446
    My Cars
    1x633, 1x E3 2 DR Racer
    First re-attempt to tune went well, post the poor result last year.

    We cleaned the spark plugs and put in 42 litres of new 98 octane fuel.

    Car struggled cold to not run rich. AFR was improved at 12:1. Warmed her up and we got the AFR closer to 13.5:1, much better than last years 10:1.

    Still a bit to do. Still running rough and an issue with a voltage drop by 1 volt when the fan kicks in. This will effect the fuel injectors so we need to work out why and fix it. The Megasquirt PRO III can compensate but we need further turning to get there. As an example, when the fan kicks in and the voltage drops at the ECU when compared to the battery, the AFR jumps from 13.5:1 to 12.5:1.

    But she is running, driveable, dirty, but we now have a solid base to work out the gremlins. In the vid where we give her a rev, we take her up to 5,000rpm, still 3k from the redline. So at redline she will absolutely scream!!!





    Here's us taking her up to 5k.



    20230218_123814.jpg
    Checking voltage drop.


    20230218_122118.jpg
    Injector cover off.
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 430hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  8. #508
    Join Date
    Dec 2005
    Location
    Melbourne, Australia
    Posts
    1,884
    My Cars
    E24, E34 x2, E36
    nice to see it running. I wouldnt be tuning it much leaner than 13:1 at full throttle at the absolute leanest. (12.5:1 is nice and safe and wont hurt power too much) Most of the power is in the timing, with very little advantage in going from. At idle and part throttle should be 1.0 Lambda (14.7:1) for best results. It would be a crying shame to damage the precious and expensive engine by tuning it too lean.

    With todays autotune programs for air/fuel (which I assume your ecu has!) and accurate wideband sensors, it should be a breeze to get it running to 95% pretty quickly, as there is no Vanos, turbocharging, or flex fuel making things overly complex to tune.
    BMWs
    90 E34 M5
    84 E24 M635csi standalone ecu with coil on plug
    94 E34 540i/6 SC 17psi Flex fuel/standalone ecu
    97 Z3 2.8
    97 E36 M3 euro SC still u/c


    OTHERS
    11 Audi S5 APR stg2
    19 Volkswagen Amarok V6


  9. #509
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,446
    My Cars
    1x633, 1x E3 2 DR Racer
    Brake kits have arrived, hopefully installed next week. Here's hoping. I'm an eternal optimist.

    331229020_545803584312560_2272131025064593505_n.jpg
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 430hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  10. #510
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,446
    My Cars
    1x633, 1x E3 2 DR Racer
    We think we've sorted the issue with the rotten tune and loss of voltage. Bad alternator and battery on the way out (according to auto electrician who went over the car last night). When the alternator is not charging (which can be any time) the tune goes horrible and the voltage drops, along with the tacho dropping to zero. So we believe that this is the voltage and tune issue we are having. The battery being older (given the last three years) is expected and a new battery is not a bad idea.

    New alternator underway, along with battery.
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 430hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  11. #511
    Join Date
    Aug 2021
    Location
    Sydney
    Posts
    1
    My Cars
    1986 E24 635csi Manual
    I had this issue on my m30 - alternator rebuilt new battery and it feels like a different car - much more power. Previously was misfiring and coughing everywhere...

  12. #512
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,446
    My Cars
    1x633, 1x E3 2 DR Racer
    Exactly what we think it is. when we start the car and the alternator is charging, we could track it. When we start the car and the alternator is not charging or, where we are running the engine and the alternator stops, it runs like a 1950's tractor. So hopefully we are right in a few weeks.
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 430hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  13. #513
    Join Date
    Dec 2005
    Location
    Melbourne, Australia
    Posts
    1,884
    My Cars
    E24, E34 x2, E36
    It will be great to have this sorted. The poor car has been through so man sets of hands since the Matt days. Hopefully she gets out driving asap.

  14. #514
    Join Date
    Aug 2008
    Location
    Sydney Australa
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    1x633, 1x E3 2 DR Racer
    New alternator in and car running perfectly (although yet to tune). Will organise the new battery but car seems very happy now. will get onto finalising the road auto-tune for the ECU.

    IMG-20230517-WA0001.jpg

    IMG-20230517-WA0005.jpg

    IMG-20230517-WA0015.jpg
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 430hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  15. #515
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,446
    My Cars
    1x633, 1x E3 2 DR Racer
    Auto-Tune of ECU organised for this Saturday from 11am. Hopefully from there we can move onto the brake upgrade and then full 90% power dyno.


    Here she is washed and ready to go (although missing front BBS centres as wheels have been off and on a lot lately).

    IMG-20230530-WA0004.jpg
    Last edited by Shipper; 05-30-2023 at 10:43 PM.
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 430hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  16. #516
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,446
    My Cars
    1x633, 1x E3 2 DR Racer
    Very productive Saturday driving. A few issues identified. Better now than on the rolling dyno striving for power. Note that;

    1. Car was running cold. Would sit at 77 degrees C and needs to be running at 85-95 degrees C. We thought the thermostat was stuck open. Turns out it's sitting in a box waiting to be installed. Yikes.
    2. Car is running at 20% idol in neutral with zero throttle, or that's what the ECU thinks so throws fuel at it. This resulted in (at 110km/h) the engine flooding on a down shift requiring a pull over and an ECU re-set.
    3. Speedo not working.

    So we need to get these issues fixed prior to the next drive. That all said the car, without any dialing in, pulled far harder than a brand new M30B35 635. As it was driven the ECU auto-tunned and within seconds became more driveable in each gear. Even down-changing the ECU tuned the engine up and every second on the road she became more powerful and far smoother.

    Photos and vids as follows;

    20230603_102413.jpg

    20230603_102425.jpg

    20230603_102430.jpg

    20230603_102510.jpg

    20230603_102521.jpg
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 430hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  17. #517
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,446
    My Cars
    1x633, 1x E3 2 DR Racer
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 430hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  18. #518
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,446
    My Cars
    1x633, 1x E3 2 DR Racer
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 430hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  19. #519
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,446
    My Cars
    1x633, 1x E3 2 DR Racer
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 430hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  20. #520
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,446
    My Cars
    1x633, 1x E3 2 DR Racer
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 430hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

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