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

  1. #351
    Join Date
    Aug 2008
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    Sydney Australa
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    2,482
    My Cars
    1x633, 1x E3 2 DR Racer
    Yee doubt?

    Photos taken by my mechanic below. But he is not the worlds best photographer.

    IMG-20190531-WA0001.jpg
    Lightened flywheel.

    IMG-20190531-WA0000.jpg

    IMG-20190531-WA0007.jpg
    Gearbox cleaned.

    IMG-20190531-WA0013.jpg
    Look what's back in the engine bay!

    IMG-20190531-WA0014.jpg
    Driveshaft in!
    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  2. #352
    Join Date
    Sep 2005
    Location
    North Carolina
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    10,579
    My Cars
    '86 M635/'10 Clubman
    I doubt nothing

    I anticipate everything

  3. #353
    Join Date
    Jul 2018
    Location
    Netherlands
    Posts
    292
    My Cars
    1982 628CSi
    It looks like you've got your mojo back!

    AustinPowersMojo.png

    Keep the good stuff coming Shipper.
    Undergoing restauration; my 1982 628CSi: https://www.bimmerforums.com/forum/s...628CSi-rebuild

  4. #354
    Join Date
    Aug 2008
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    1x633, 1x E3 2 DR Racer
    A few more shots.

    Need to get a few specialist brackets made to hold everything in the engine bay. Too many clashes. Steering arms hitting extractors hitting power steering box. Those sort of things.

    20190601_093721.jpg

    20190601_093709.jpg

    20190601_093650.jpg

    20190601_092622.jpg

    20190601_092758.jpg
    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  5. #355
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,482
    My Cars
    1x633, 1x E3 2 DR Racer
    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  6. #356
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,482
    My Cars
    1x633, 1x E3 2 DR Racer
    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  7. #357
    Join Date
    Aug 2018
    Location
    Adelaide
    Posts
    30
    My Cars
    1986 BMW 635 1976 911
    Looking great Josh
    Youre back mate!!! Well done

  8. #358
    Join Date
    Aug 2008
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    Sydney Australa
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    1x633, 1x E3 2 DR Racer
    Work still ongoing. Wiring at the moment and slow going. We have asked 3 auto-electricians to quote the works and none will respond, so we go alone. I posted on the Australian e24 FB site for recommendations for a good auto-electrician and the crickets did not even turn up.

    Separate to that, raced the E3 3.0s Coupe yesterday. Was in Class 'D'. Fastest in class 'D', 'C' and 'B'. This car is still over weight and runs original brakes and sports shocks/springs. Would level peg the 135i and M3 race cars down the straight. Real potential. See the Classic E3/E9 section on Bimmerforums.
    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  9. #359
    Join Date
    Aug 2008
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    Sydney Australa
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    1x633, 1x E3 2 DR Racer
    Raced my E3 3.0s 2 door on the weekend. It was a rocket. Runs a hybrid M30B35 Group A/C engine. 347hp and the car weighs around 1230kg. An absolute blast to race. Felt like a fast go-kart. The 633 progresses slowly.

    66308238_2347137015501339_2242374473594437632_o.jpg
    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  10. #360
    Join Date
    Jun 2010
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    Reykjavik Iceland
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    1,614
    My Cars
    ALPINA B10 BITURBO
    You have been through a lot i can see
    Sveinbjörn Hrafnsson

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

  11. #361
    Join Date
    Aug 2008
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    1x633, 1x E3 2 DR Racer
    Next month is the 1 year anniversary of the engine coming back. So I posted on the Facebook Megasquirt Forums and Aaron replied stating that he and his gorgeous partner Kate would be happy to help. They are a couple who suprersprint their cars and have completed a number of megasquirt builds and installs.

    So we are going to do a complete re-install of the megasquirt and then get a base tune running. Then off to the rolling road. This will happen slowly given that Aaron and Kate can only spend a night a week at best but I'm very grateful for that given nearly 7 calendar years of delays.

    Let's see how we go.
    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  12. #362
    Join Date
    Jul 2018
    Location
    Netherlands
    Posts
    292
    My Cars
    1982 628CSi
    Can't wait for the update messages
    Undergoing restauration; my 1982 628CSi: https://www.bimmerforums.com/forum/s...628CSi-rebuild

  13. #363
    Join Date
    Aug 2008
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    Sydney Australa
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    1x633, 1x E3 2 DR Racer
    Megasquirt is being picked up tomorrow. Full diagnostics to follow. Then a firmware update as it is running 2017 software and Aaron will update it to 2019 software, which removes a few bugs.

    We know the engine is good. We know the wiring loom was brand new but now has a few alterations. Aaron is taking a step by step methodical approach.

    Step 2 will be to remove the Megasquirt supplied loom and see what everything is. Then compare to the wiring diagram for this engine. Aaron is also looking into the fuel injectors to see what they are and what their top spec is. This will give him parameters for the programming of the megasquirt.

    I sent Aaron the start up file provided to me by a fellow S38 6'er tragic. I may have gotten the wrong file and, I do not know if the original tuners (who ran around in circles and stuffed up my engine) even used it but;

    1. Engine displacement was incorrect. But the supplied startup file was for an S38B35. I'm now a little over 3.8 litres. So no error here. Just not corrected by the original tuners.
    2. AFR of 10.3:1 was way out. It should be the stoic value for fuel and in this case 14.7:1.
    3. Squirts per cycle should be one for sequential. Was set at 2. Explains why fuel ran up the dyno exhaust and set the roof of the adjoining room on fire.
    4. Injector staging should be simultaneous for sequential. Was programmed wrongly.

    Aaron will review what was changed by the last tuners from the above and this will give us a good idea as to what went wrong.

    More to come.
    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  14. #364
    Join Date
    Aug 2008
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    Sydney Australa
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    1x633, 1x E3 2 DR Racer
    Engine install finalised. Started. Videos below.

    Note that these startups are based on the engine with tuning issues as noted above. The following will start tomorrow;


    1. Aaron to pick up ECU and check tune file.
    2. Startup tune file had huge issues. Aaron to see what the file looks like now.
    3. Aaron to do ECU diagnostics to make sure no issues.
    4. Aaron to update firmware from 2017 to 2019.
    5. Aaron to make good startup file as Megasquirt has a self tune mode. We can then do some self tuning.
    6. Aaron to research engine and fuel injectors to work out this base tune.
    7. Aaron to then go through wiring loom and re-wire engine.
    8. Testing, then startup.
    9. Further testing. Maybe a short 20min drive to self tune if we can.
    10. Then when we think we have the tune as good as we can, off to the dyno for some power runs and then the performance tunes.


    And here are the vids taken today, pre any ECU/Tuning.




    Last edited by Shipper; 09-18-2019 at 01:29 AM.
    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  15. #365
    Join Date
    Aug 2008
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    Sydney Australa
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    1x633, 1x E3 2 DR Racer
    Aaron, Cate and Elie the mechanic hit the car for 3 hrs last night. Aaron noted that the injectors were programmed in as 110cc (they should have been around 290cc) and there were lot's of other issues. The car is running but needs heaps of work before heading to the dyno. We are considering 550cc injectors and Elie believes at least one of the current injectors is leaking, hence a very large backfire at the end of testing.

    Video's may not be in order. Still a little missfire and the wiring is a mess as you can see. But we now have a running car we can work on and tune. Lot's of wiring. Sensors need to go in for the tune. More to come.

    We still need to turn the car off by pulling wiring. So a few problems there.




    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  16. #366
    Join Date
    Aug 2011
    Location
    Ireland
    Posts
    111
    My Cars
    M3
    It's alive !!!

    Great moment in the project. Getting closer to the first drive. Best of luck with it.

  17. #367
    Join Date
    Aug 2008
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    Sydney Australa
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    1x633, 1x E3 2 DR Racer
    Current injectors are a mess. Additional to new 525cc injectors will be a Bosch motorsport pump and new lines. Old injectors below for ref.

    IMG-20190927-WA0008.jpg

    IMG-20190927-WA0011.jpg

    IMG-20190927-WA0012.jpg

    IMG-20190927-WA0013.jpg
    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  18. #368
    Join Date
    Jul 2018
    Location
    Netherlands
    Posts
    292
    My Cars
    1982 628CSi
    I'm just surprised that your previous engine guy made such a mess, he sounds like he's never done it before!
    You're lucky you found an experienced mechanic to get it working.

    Keep it up, let's see that dyno explode!

  19. #369
    Join Date
    Aug 2008
    Location
    Sydney Australa
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    1x633, 1x E3 2 DR Racer
    Unfortunately the engine needed a complete rebuild. Fortunately the complete rebuild will be race endurance quality.

    We are currently working out which of the two injectors will best fit on the fuel rail. Additionally we are getting a Bosch 044 motor sport fuel pump. Getting rid of the old 633 pump will help.

    So either top right or bottom left for the fuel injectors. See this link. https://www.injectorsonline.com/au/f...l?cc_rating=62

    I'll get the genuine pump but here's a link to the non genuine one. https://www.injectorsonline.com/au/n...-at-5-bar.html

    These guys have all the fuel lines/hoses/clips/ etc. https://www.efihardware.com/products...-hose-and-Pipe
    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  20. #370
    Join Date
    Dec 2005
    Location
    Melbourne, Australia
    Posts
    1,903
    My Cars
    E24, E34 x2, E36
    Nice to see it close Josh.

    Its always hard when the car sits around as many things don’t function well when this happened. 55cc/minn will give nice headroom to evenrun flex fuel on e85 to allow plenty of timing. I’ve been running e85 for around 18 months in the boosted e34 only taken out 3deg of timing with 10:1 comp and 16psi of boost. The knock sensors never pull timing out even in hot weather. I’m sure the computer can deal with flex fuel. There would be significant advantages to run on a 50/50 blend with 98 and still retain good cruising range
    Last edited by GazM3; 10-07-2019 at 06:03 AM.
    BMW’s
    90 E34 M5
    84 E24 M635csi standalone ecu with coil on plug
    94 E34 540i/6 SC 5-17psi Flex fuel/standalone ecu
    97 Z3 2.8
    97 E36 M3 euro SC still u/c


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  21. #371
    Join Date
    Aug 2008
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    Sydney Australa
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    1x633, 1x E3 2 DR Racer
    I had the original injectors tested. Of the 6 injectors 3 were stuck open and 3 only fired intermitantly. There was no way we were ever going to get the car tuned with those. Bosch 550cc injectors (brand new and a direct fit) on there way.
    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  22. #372
    Join Date
    Aug 2008
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    Sydney Australa
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    1x633, 1x E3 2 DR Racer
    The 550cc Bosch injectors were unavailable so I've got (and received) the XSpurt 550cc injectors. The 5psi Bosch 044 motor Sport pump is also in. So across to the mechanic tomorrow to get all hooked up. Should be testing next Thursday.
    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  23. #373
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,482
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    1x633, 1x E3 2 DR Racer
    The XSpurt 550cc injectors were too short and extended too far into the engine. So these have been couriered back to injectors online and, I've also sent an original injector so they can be matched. So the corrected shape 550cc injector set should be sent back asap. This honestly never ends. Everything needing to be done 3 times. Yee Gawds I hope it rockets along!
    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  24. #374
    Join Date
    Aug 2008
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    Sydney Australa
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    1x633, 1x E3 2 DR Racer
    New 550cc injectors are in and engine runs. No backfire. I would not say it is smoother, actually sounds far more aggressive.

    The section of twin exhaust immediately behind the extractors has been removed to place the two oxygen sensors. We have one to place immediately and will finalise the base tune with it, installing the second as soon as it arrives.

    We should be finalising the base tune this Thursday night. No holding your breath here people.
    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  25. #375
    Join Date
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    1x633, 1x E3 2 DR Racer
    Motorsport fuel pump in.

    550cc injectors in.

    Sensors welded in and ready for ECU leads. I'll run two oxygen sensors for the final dyno runs but as we only have one at the moment (from the PLX multi-gauge set https://www.plxdevices.com/ProductDe...02726&CartID=1 ), we'll do the base tune with just one in.

    Tuning at the mechanics tonight.

    20191113_122646.jpg

    20191113_122649.jpg
    1977 633 CSi RHD Euro. S38B38 3.9L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 417hp, 369lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

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