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Thread: 4.6is M62B46 into '03 540it. From day one.

  1. #1
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    4.6is M62TUB46 into '03 540it m-sport. From day one.

    As an introduction:



    I bought this car from a couple I'd known for years. I'd seen the car and heard it but was happy enough with my 735i to not be too interested in asking about it.



    A few years later while trying to replace the 7 after major mechanical issues I was unable to rectify I bought a 540i. It wasn't what I wanted or was looking for but I quickly fell in love.



    I drove this for a couple years. I bought it in decent shape but did what I could to really make it a great car. I fixed everything on the interior and exterior and pep'ed it up with a full Dinan intake package including software for the slushbox and engine. Loved this car, enough to toss $6k into it one month.
    The owners of the wagon who swore to me that it was a factory M5 e39 had me intrigued but not enough to investigate the validity of that story but I'd fallen in love/lust with it but they loved it also and told me they would never part with it.
    A few weeks after spending all my spare cash on my 540i, I was informed that the couple were getting a divorce and the wagon was for sale.

    I still knew nothing about tourings and wasn't prepared to make an offer on it, not an educated one anyway. I was put on the spot, "buy it now or we've got buyers lined up. We've seen how well you've taken care of your 540i and we'd like you to have it but we need it gone asap"
    No pressure.

    I put my 540i up for sale on CL and found a mechanic who upon hearing I was buying an M5 touring was skeptical and offered to come with me for my first under-the-hood look. So you can imagine how that went. Dur... But, he said that the car had an Alpina 4.6 engine.
    The owners claimed ignorance and fed me a story of this Wagon being used as a shuttle for the Overseas delivery program and BMW had added the Alpina engine to up American interest in wagons which weren't selling all that well in N. America. Then, it was sold to a dealership, to a private owner and then to them. Mostly B.S. but, I fell for it. I mean a BMW tech and the owners claimed 4.6 Alpina so what did I know? I bought it and sold my car to a friend. (He lives close enough to me that I get to see my old car, dirty, once a month or so. Sucks)

    The car was a 4.4 ltr 540it m-sport plain and simple. It started in New Jersey as a Drive For the Cure cancer fundraiser car, owned by BMW of N America. This is the actual car back then.



    So, 25k miles later it went to Crevier BMW in California and to a Lawyer and his wife. He turned it into the M5 clone with the dual exhaust, M5 mirrors, staggered wheels and added the "M" badge.

    More on the exhaust :
    http://www.bimmerforums.com/forum/sh...ting-the-floor

    The couple I bought it from bought it from the California couple and now it's mine.
    https://youtu.be/YGxF_sH_Xrg

    https://youtu.be/plWvxBfNk9I

    https://youtu.be/ZrUJEyIbsjM

    Not an M5 but fun to drive and I'm in love with the wagon.

    All was fine in my world until...



    My wife bought her 1st BMW, a 4.6is X5. I didn't think I would but I really like it and when she was tired of pouring $ into it I had the idea of swapping her 4.6 for my 4.4 or supercharging my wagon...


    She kept her engine and X5 but guess who couldn't stop mentally grinning since thinking about the prospect of the swap and who just bought an M62B46 4.6 engine tonight... This guy!!

    So, I'll be refreshing my m62tub44 first and selling it in a rolling chassis while refreshing the 4.6is and repairing the damage I caused in my first accident since I was 16. I'm 42 currently.



    The motor arrives next week. Next Tuesday I'll begin to tear the 4.6 apart preparing to rebuild it.
    I'll replace all worn parts I can find and take my que from Alpina and have the heads ported and polished. I'll try and make sure the weights of the valves and rods are as dead similar as possible.

    The supercharger for the 4.6 will be next year's project. Oh yeah, that's happening.

    Before I get started, a few things;
    I'm not a mechanic, BMW expert, psychic, or master fabricator.
    I'm keeping the automatic transmission.
    I'm not interested in using an S62.
    I'm keeping the "M" badge. It reminds me that I can be easily fooled/gullible at times. Plus if all goes well with the swap and addition of the s/c I'll be happy to race any and all true M5's and either humble or honor the badge. I also enjoy the conversations it precipitates at intersections and parking lots.
    This is my DD and needs to be "right"
    I do all my posts here on my phone so spelling and grammar nazis can kiss my Asterix.
    I don't have a garage.
    I work really hard physically for my money and it isn't much compared to some. Every dime needs to count.
    I'm sarcastic at times but I'm not a mean person.
    Why a 4.6 and not a supercharger?

    http://www.bimmerforums.com/forum/sh...F-supercharger

    I'm as scared as I am excited.


    Any and all help is supremely appreciated and accepted. Free food and beer to any and all willing to come help.

    Thanks for your time. Wish me luck.
    Last edited by Plattus1000; 07-10-2017 at 11:32 PM.

  2. #2
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  3. #3
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    Great, more pressure! - transportador


    So, here's what I've heard so far;
    Electronics and induction are basically the same. The 4.6 intake is the same piece that Dinan sells for the M62TU and BMW installed on the M60 engine.
    The biggest challenge was the oil pan and crankcase ventilation system as the truck and car systems are different. Alot of small parts need to be changed including the oil pump, pump chain, oil pan and valve covers.
    Right cover 4.6is 11121703172
    Left cover 4.6is 11121703179
    Right cover 4.4 11121703172
    Left cover 4.4 11121703175
    So they're different but in what ways...?

    Software is another story since BMW never put this engine in front of a manual trans. An automatic car would be a piece of cake.

    Engine mounts bolt to the block using the same holes, no problem there.
    Accessories mount the same also, no problems.
    Wiring harness connections are all the same, assuming that the E39 has an M62TU engine not an M62. 4.4 and 4.6 DME's are the same basic hardware number. X5 software does not perform well with a manual transmission.
    I.m using 4.4L m62tub44 w/automatic transmission so, all good

    Parts list is kind of extensive. Mostly to fix differences with the oil pan which shouldn't be too difficult to replace with an e39 pan and plumb for pumps and cooling.


    To the question of if this is worth the trouble... Why not an S62 or just s/c the 4.4?

    The 4.6-liter V-8 was engineered with some inspiration from Alpina, BMW's factory-anointed aftermarket tuner in Buchloe, Germany.

    Like Alpina's own 4.6-liter B10, the factory's DOHC 32-valve variant is a riff on the current M62 V-8 found in the X5 4.4i and 540i. The crucial difference is that each pot now displaces 577cc instead of 550cc, due to 1.0mm more of bore and 2.3mm more of stroke. A compression-ratio increase of 0.3 to 10.5:1, a looser exhaust, huge m60 intake manifold, and lumpier intake cams backed up by a more aggressive mapping of the engine's cam-phasing mechanism account for a rating of 340 horsepower, 50 more than in the 2002-03 4.4i, which went to 290 from 282 horsepower in the facelift.

    The crankshaft also turns another 26 pound-feet, for 350 total. That coupled with my 5-speed automatic ZF 5 HP 24 EH to a 3:15 diff and an LSD should launch me pretty nicely.

    This motor I bought isn't like new, fully refreshed for $6,5k all installed (fingers crossed). I have a friend/shop to do the work minus the coding. I'll be helping as much as I can to learn and cut down on costs.

    The 4.6is has a true 50hp more than the 4.4 from key turn to 6,700rpm and is built as well if not better slightly than the 4.4.

    So, spending $2k to refresh the 4.4 and another $6-7k on the s/c with potential tuning issues verses $6-7k on the 4.6is swap and selling my perfectly running 4.4 for $1-2k to offset the cost seems to make sense to me at this point.

    Getting to say I have a 4.6is wagon, priceless to me and potentially adding a s/c @ a later date to hit 450-500hp down the road makes me emotionally erect a little bit.

    Yes, worth it, to me

    - - - Updated - - -

    Last week I bought the wavetrac lsd and am installing it this week.

    At some point in all this I'd like to add headers and look for decent performance cats to lay a foundation for the s/c down the line.
    Refresh the suspension and have a very torqe-rich wagon giving the lsd a good workout.

    I'm getting ahead of myself.

    - - - Updated - - -

    Parts and whatnot:
    part one ----------------


    4.6 block with pistons - 11117512872 - specific to x5 4.6is
    4.6 lower cover - 11141708209 - used on e38/e39/e53

    4.6 upper timing covers 11141745506 / 11141745509 - used on e38/e39/e52/e53
    4.6 valley cover - 11141742042 used on e31/e32/e34/e38/e39/e53)
    4.6 rear upper seal cover/gasket 11141729832/ 11141729836 used on e31/e32/e34/e38/e39/e53)
    4.6 rear main seal 11141710247 - used on e31/e32/e34/e38/e39/e53)
    4.6 lower pan 11137500210 - specific to 4.6

    4.6 cyl gasket 11127519410 / 11127519406 - specific to 4.6 and e52 alpina
    4.6 cyl head 11127512607 / 11127512608 - specific to 4.6

    4.6 crank with shells - 11217512876 - specific to 4.6
    4.6 connecting rods - 11241725809 (used on e31/32/34/38/39/53)
    4.6 piston alusil mahle - 92.98mm - 11257512411 (specific to 4.6)


    ------------------ part two : valve train and cams ----------------


    alpina intake cam 11318025823 / 11318025824 specific to alpina e52
    alpine exhaust cam 11317513235 / 11318025824 specific + x5 4.6is

    x5 4.6is intake cam 11317513227 / 11317513231 - specific to 4.6is
    x5 4.6is exhaust cam 11317513235 / 11317513238 - specific to alpina e52 + x5 4.6is

    e52 alpina valves
    INTAKE VALVE 35,0/5,94MM 11341435480 (same as on e31/e32/e34/e38/e39/e52 alpina/e53 4.4i and 4.6is)

    EXHAUST VALVE 30,5/5,94MM 11341435482 (same as on e31/e32/e34/e38/e39/e52 alpina/e53 4.4i and 4.6is)

    Hydraulic valve lifter 11321440256 (same as on e31/e38/e39/e52 alpina/e53 4.4i and 4.6is) (note, not the same as the e32/e34)
    Last edited by Plattus1000; 11-28-2015 at 05:13 AM.

  4. #4
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    Glad you ended up deciding what you want to do and seem committed to getting through it! Subscribed
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  5. #5
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    Looking forward to this. Subscribed.

  6. #6
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    Quote Originally Posted by Tutti57 View Post
    Glad you ended up deciding what you want to do and seem committed to getting through it! Subscribed
    Me too, nerve racking choice in my world.

  7. #7
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    Have you decided on how you're going to tackle the software?

    Right now the strategy I'm thinking is figuring out the differences between a 540iA and X5 4.4i tune, and then porting those differences over to an X5 4.6 tune. In cases where the 4.4 differs from both, some extra investigation will be required.

  8. #8
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    Quote Originally Posted by TerraPhantm View Post
    Have you decided on how you're going to tackle the software?

    Right now the strategy I'm thinking is figuring out the differences between a 540iA and X5 4.4i tune, and then porting those differences over to an X5 4.6 tune. In cases where the 4.4 differs from both, some extra investigation will be required.
    I honestly don't know. The 4.6is tune is designed for a much heavier vehicle and the 540ia tune is more for a smooth acceleration curve.
    In reality, I was going to go with a 4.4 custom (Dinan-ish) but I'll defer to people that own more than my $65 code reader to push me in the right direction.

    Also, will I need to do some flashing of the transmission software also and what kind?

    This is clearly not my forte' but there is a guy who did this swap in a e39 540i and possibly an e38 so I know there's a way.

    Here's a guy in '08 who put a 4.6is block in his e39 540i
    http://www.bimmerfest.com/forums/sho...d.php?t=290730
    He doesn't discuss ecu' s but it's a good read.
    Last edited by Plattus1000; 01-10-2017 at 11:42 AM.

  9. #9
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    I remeber jicaino who put in a 4.6 in his 540iA.



  10. #10
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    Plattus, looks like I'll be in the market for b46 oil pan. Will you be selling yours soon? If so, please pm me your price. I'll cover shipping with my fed ex account





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  11. #11
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    Quote Originally Posted by Plattus1000 View Post
    I honestly don't know. The 4.6is tune is designed for a much heavier vehicle and the 540ia tune is more for a smooth acceleration curve.
    In reality, I was going to go with a 4.4 custom (Dinan-ish) but I'll defer to people that own more than my $65 code reader to push me in the right direction.

    Also, will I need to do some flashing of the transmission software also and what kind?

    This is clearly not my forte' but there is a guy who did this swap in a e39 540i and possibly an e38 so I know there's a way.

    Here's a guy in '08 who put a 4.6is in his e39 540i
    http://www.bimmerfest.com/forums/sho...d.php?t=290730
    He doesn't discuss ecu' s but it's a good read.
    Well I went ahead and tabulated the 4.4i vs 540iA differences

    The majority of the differences can be placed in three broad categories:
    Catalytic converter heating/monitoring
    Tank leakage pump
    Cruise control regulation

    It should be safe to use the 540i values in the 4.6is tune for those.

    However, there are also some differences in knock control and lambda targets. And while I haven't examined the 4.6 software closely yet, these are likely unique to all 3 variants. My gut feeling is that it would be safe to use the stock 4.6is values for these categories, though I would prefer to know why the knock and lambda targets are different at all.

    I don't think personally it'd be a good idea to just use a dinan 540i tune. For the transmission software, dinan or alpina would probably be appropriate.

  12. #12
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    Quote Originally Posted by Trasportador View Post
    Plattus, looks like I'll be in the market for b46 oil pan. Will you be selling yours soon? If so, please pm me your price. I'll cover shipping with my fed ex account
    You sir can have it for the cost of shipping and one good pint at my local micro brewery. Let me get to that bridge before I cross it.

    - - - Updated - - -

    Quote Originally Posted by TerraPhantm View Post
    Well I went ahead and tabulated the 4.4i vs 540iA differences

    The majority of the differences can be placed in three broad categories:
    Catalytic converter heating/monitoring
    Tank leakage pump
    Cruise control regulation

    It should be safe to use the 540i values in the 4.6is tune for those.

    However, there are also some differences in knock control and lambda targets. And while I haven't examined the 4.6 software closely yet, these are likely unique to all 3 variants. My gut feeling is that it would be safe to use the stock 4.6is values for these categories, though I would prefer to know why the knock and lambda targets are different at all.

    I don't think personally it'd be a good idea to just use a dinan 540i tune. For the transmission software, dinan or alpina would probably be appropriate.
    Is there a hug emoticon?
    I have no idea what lambda is with regard to engine management.
    I'm grateful for your interest and knowledge.

    - - - Updated - - -

    Quote Originally Posted by auaq View Post
    I remeber jicaino who put in a 4.6 in his 540iA.
    Let's get him in here!
    Last edited by Plattus1000; 11-29-2015 at 10:05 PM.

  13. #13
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    Quote Originally Posted by Plattus1000 View Post
    Is there a hug emoticon?
    I have no idea what lambda is with regard to engin management.
    I'm grateful for your interest and knowledge.
    Lambda sensors = O2 sensors, so a target lambda is essentially a target AFR.

    PM me when you're ready to deal with the electronics and I can probably set you up with a "546i" tune. As I mentioned, my gut says it's probably fine to use the stock 4.6is knock and lambda values. In the worst case, you could probably strap the car on the dyno and have a tuner tweak those values to be perfect.

  14. #14
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    I wish I could but he has stopped posting quite some time ago.



  15. #15
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    Quote Originally Posted by TerraPhantm View Post
    Lambda sensors = O2 sensors, so a target lambda is essentially a target AFR.

    PM me when you're ready to deal with the electronics and I can probably set you up with a "546i" tune. As I mentioned, my gut says it's probably fine to use the stock 4.6is knock and lambda values. In the worst case, you could probably strap the car on the dyno and have a tuner tweak those values to be perfect.
    That's amazing. Thank you so much for your offer and time. Air fuel ratios, got it.

    - - - Updated - - -

    Quote Originally Posted by auaq View Post
    I wish I could but he has stopped posting quite some time ago.
    Some people... They get what they want and bounce. I'll be here long after this is done. It's my only social media outlet.
    Last edited by Plattus1000; 01-31-2016 at 07:51 PM.

  16. #16
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    I found Jicaino

    Quote Originally Posted by auaq View Post
    I remeber jicaino who put in a 4.6 in his 540iA.
    His reply to my initial questions:
    "Hey! you need to replace the lower pan with the one now installed in your B44. While at it, get a new oil pump and return and feed tubes, the oil pumps are different. You need to splice out and then in a new oil pump chain, if you don't want to mess with leaks later you could do the front seal while replacing the pan and be done with it.

    I have an alpina DME"
    Said it was a fun car, "like an M5 with an automatic"
    I'll assume not exactly but damn close to an accurate description of the feel.

    Thanks Auaq.

  17. #17
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    No problem.



  18. #18
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    All ears

  19. #19
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    Quote Originally Posted by TerraPhantm View Post
    Well I went ahead and tabulated the 4.4i vs 540iA differences The majority of the differences can be placed in three broad categories: Catalytic converter heating/monitoring Tank leakage pump Cruise control regulation It should be safe to use the 540i values in the 4.6is tune for those. However, there are also some differences in knock control and lambda targets. And while I haven't examined the 4.6 software closely yet, these are likely unique to all 3 variants. My gut feeling is that it would be safe to use the stock 4.6is values for these categories, though I would prefer to know why the knock and lambda targets are different at all. I don't think personally it'd be a good idea to just use a dinan 540i tune. For the transmission software, dinan or alpina would probably be appropriate.
    well then knock target would be different because the compression is higher therefore more likely to knock

  20. #20
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    The 4.6 has a higher CR?



  21. #21
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    Quote Originally Posted by auaq View Post
    The 4.6 has a higher CR?
    Due to 1.0mm more of bore and 2.3mm more of stroke. A compression-ratio increase of 0.3 to 10.5:1
    Pay attention man! lol
    Last edited by Plattus1000; 12-01-2015 at 10:45 PM.

  22. #22
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    I don't think that's how you measure or guesstimate a CR based on bore x stroke numbers. The two things are completely different and not even closely related.

    Just because it's slightly bigger than a B44 doesn't mean that the compression ratio has to be higher, or even lower. It may in fact remain the same as a B44. A lot of power can be had with extra, bigger capacity (for sure), with different cam profiles (duration + lift), Vanos tuning (LSA, valve overlap, etc.), intake and exhaust valve size, intake and exhaust port geometry (how good the head flows or breathes). Yes, a higher CR can help in making more power, but these are some of the contributing factors that should be taken into account as well. Anyways, curious to know what is the actual CR of the 4.6 engine.




  23. #23
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    Quote Originally Posted by TerraPhantm View Post
    Lambda sensors = O2 sensors, so a target lambda is essentially a target AFR.

    PM me when you're ready to deal with the electronics and I can probably set you up with a "546i" tune. As I mentioned, my gut says it's probably fine to use the stock 4.6is knock and lambda values. In the worst case, you could probably strap the car on the dyno and have a tuner tweak those values to be perfect.
    I'm betting the CAT heating and lambda values are different because the cats are much closer to the heads on the X5. The headers are very different than the 540i and so maybe they needed to adjust for that.Take a look at RealOEM for the differences in the headers.

    - - - Updated - - -

    OP, I like your approach to this swap, as it's similar to how I started my S62 swap. Those people who ask if a swap is possible or "worth it", might as well not do the swap. Those that say, "Hey, this has been done at least once before, so why not do it... Oh, and I already bought the engine and am getting ready to install it" are the ones that have my respect I did my quiet research on the S62 swap in an e38 before even announcing I was doing the swap. Actually, I had already started the swap before I posted the thread on it.

    TerraPhantm, just out of curiosity, couldn't you compare the differences between a 4.4 auto and 4.4 manual and apply the same changes to a 4.6 tune to make it work with a manual properly? Don't go out of your way to do this for me as I'd probably opt for a S62 with a manual in any project I would consider this for, but my logic says that it could be done.

    -Paul
    2003 "M5" - Full M5 conversion, AMG C63S 6 piston front calipers, Porsche Panamera 4 piston rear calipers, GC Coilovers,
    Eibach ARBs, UUC Evo3/DSSR, Borla Exhaust w/Muffler Delete, BMW NBT with Carplay/Android Auto, Bi-Xenons, e38 Style 37 M-Pars, e60 Hubs 530i 6-speed swap build thread
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  24. #24
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    Quote Originally Posted by auaq View Post
    I don't think that's how you measure or guesstimate a CR based on bore x stroke numbers. The two things are completely different and not even closely related.

    Just because it's slightly bigger than a B44 doesn't mean that the compression ratio has to be higher, or even lower. It may in fact remain the same as a B44. A lot of power can be had with extra, bigger capacity (for sure), with different cam profiles (duration + lift), Vanos tuning (LSA, valve overlap, etc.), intake and exhaust valve size, intake and exhaust port geometry (how good the head flows or breathes). Yes, a higher CR can help in making more power, but these are some of the contributing factors that should be taken into account as well. Anyways, curious to know what is the actual CR of the 4.6 engine.

    You know or I hope you know I'm just kidding with the "pay attention" thing. http://m.caranddriver.com/reviews/bm...take-road-test
    Now I assume they got the info from BMW but it seems consistent with everything I can find.

  25. #25
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    Now I see what ya mean .....

    - - - Updated - - -

    Now we need someone to put in a M62B48 out of an Alpina roadster or a B10 and into a wagon or a sedan!



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