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

  1. #76
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    Quote Originally Posted by blackknight530i View Post
    They are Alusil, not Nikasil as far as I knew. Only the pre-95 m60 blocks were Nikasil I think.
    I think you're right. I think the early ones were Nikasil and the later ones were Alusil.



  2. #77
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    In any case of X-sil lining of the cylinders, I meant the honing of the intake and exhaust ports as described here:
    http://boneheadperformance.com/extrude-honing/

    They're not local but after they're done, I'll have another local shop do the 3 angle grind valve job.

    Earl's Machine shop in Burien, WA.

    The valve covers will be done by these guys:Millennium Plating Company, Inc.
    http://www.magplate.com/index.htm
    They specialize in magnesium and the process doesn't have an issue with high and low spots on corners or edges. It should be pretty cool once finished.
    Last edited by Plattus1000; 01-19-2016 at 03:21 PM.

  3. #78
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    A couple of (late) fyi's from my B46->E31 project...
    * The B46 got the earlier non-vanos intake with the wider runners (read: higher HP, lower torque, all else equal, which it's not). Not a sourcing problem for me since I was swapping from the non-vanos B44. {ed: Got dopey, my B46 came with manifold, therefore I now have two "high HP" intakes and no "high torque" intake.}
    * My B46 got converted to internal PCV cyclone because...
    - The cyclone drain-back problem is solved.
    - The X53 has the hoses draped over the top, creating a conflict with the lower profile acoustic cover.
    - The regardless of the taller cover, the original hoses had gotten cooked up there, flattening out into a sticky mush.
    IIRC, I borrowed the e39 left valve cover which had a blocked dummy-port (which then punched into my e31 wire box, lol).
    * Since I was sneeking up the power curve as I iterated my software and compared dyno to road result, I can tell you it takes a significant change in power (like 20hp, 20 ftlb) to make the vehicle feel any different. So if you are contemplating changes smaller than this, don't bother. My unsolicited advice: come back later if you want to fuss.

    What to do with this?


    Pic note: the PO had already replaced one hose with generic bulk, but also got the connections flipped.


    Lol, dummy e39 VC port punching into e31 wire box, left VC.
    Last edited by Hyper; 01-10-2016 at 01:50 PM.

  4. #79
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    Hyper--- Thanks. I'll pass this and all the technical stuff on to James the mechanic and let him deal with said issues.

    Tonight we pulled the heads and oil pan off. I was pleased with the views.








    The lobes looked good on the cams and the lifters were in great shape.




    Cylinder walls looked good too. I'm very relaxed after seeing them.

    The crank was in good shape as well.
    So, time to clean these and send the heads off.
    I can't do too much till they come back and that'll take about 2 weeks. Till then I'll be buying parts to put on the completed engine. I can't stand waiting but it'll be full-on swap time when they come back home.
    Last edited by Plattus1000; 07-11-2017 at 12:08 AM.

  5. #80
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    Clean is all I can say. This engine looks really good and healthy on the inside.



  6. #81
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    This b cool

    Just listen to the sound of the engine. Isn't that the answer? If you don't understand it, it's not my problem". alex zanardi

  7. #82
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    Ok, so when I started this project we were days away from selling our business and that fell through at the last minute. I had budgeted out a decent amount for this swap at that time and now I'm counting my pennies.

    Although I can afford the extrusion hone, I can't afford the hone, the shipping there and back and then the cost of a valve job and port matching once they come back from the extrusion hone. It would cost as much as the whole engine if done to the highest standards.

    (if you're doing this swap and want all the bang, go with maxsil or molly pistons, extrude hone, valve grind, rod balancing and port matching)

    I will use Earl's machine shop in Burien WA for a resurfacing, rod balancing, 3 angle grind on the valve seats and new guides installed. I'll pass on the hone and port matching as a result of the insane cost and my time constraints. On a personal level I'm saddened and humbled but I can't do what I can't afford.

    I drop the heads off this afternoon a wiser but slightly disappointed guy.

    - - - Updated - - -

    I just dropped off my heads and I'm looking for a place to sandblast the valve covers.

    I bought the gasket set for the upper end today, cost was $140 out the door.
    Last edited by Plattus1000; 02-04-2016 at 05:19 PM.

  8. #83
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    Dropped off the valve covers at a shop to wash and bead blast them today. I'll pick up the heads and vc's on Tuesday if all goes well.

  9. #84
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    Looking forward to updates.



  10. #85
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    I've been watching this thread as it goes through the paces, rootin for you man!
    Could you do some quick measurements for me when you have the thing apart?

    I'm looking for the piston height (positive or negative in mm) at the deck at TDC.
    And the max depth of the valve relief cutout on the intake and exhaust on top of the piston.
    Would be greatly appreciated!
    Last edited by whiteghost1; 01-16-2016 at 06:24 PM.

  11. #86
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    Try M5 or not... it's... so beautiful

  12. #87
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    I'll ask James. He'll know what you're talking about. It's Greek to me I'm afraid.

  13. #88
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    Quote Originally Posted by Plattus1000 View Post
    I'll ask James. He'll know what you're talking about. It's Greek to me I'm afraid.
    Did your friend have the opportunity to take those measurements by chance?
    How's the progress coming along?

  14. #89
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    Quote Originally Posted by whiteghost1 View Post
    Did your friend have the opportunity to take those measurements by chance?
    How's the progress coming along?
    Hi, no not yet. He had a big project creep in this weekend and didn't get to it. I'll be @ his shop this weekend and I'll try to get that info for you.

  15. #90
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    Technically, this is installed right?

    Still need to send the v/c's off but I am going to try and sand them a bit first.

    Next step is pulling my 4.4 out and getting used to the idea of owning 2 engines and one rolling paperweight for a while.

    Very scary stuff for me.
    Last edited by Plattus1000; 07-11-2017 at 12:09 AM.

  16. #91
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    Clean and shiny!



  17. #92
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    Whiteghost---
    I need to put the flywheel on before I can get a TDC measurement. Give me a few days. BTW, did you need the measurements from the 4.4 or the 4.6?


    So, updating here. The v/c's for the 4.6 are the same on the passenger side but not the driver's side. On the 4.6, its missing the positive terminal so I'm going to have to use the ones off the 4.4. Although the v/c's from the 4.6 are clean and ready to be coated, there's a mess of casting marks on the fronts and I'd need to sand them pretty well to make any sense of nickel coating them. Crinkle paint or a powder coat might cover the marks just fine but not a mil thick nickel coating. So, it might be a blessing in disguise. I'll get to see what mine off the 4.4 look like and see if they're better. So, I'll be selling one set after this.

    The heads came out really nice and I'm really happy with the work @ Earl's machine shop in Burien W.A.


    The total for the valve job, surface refinishing and 3 angle grind was $440 out the door.







    (WARNING) don't take off more than a millimeter or the guide covers will be a biscuit and a half to line up right.








    My car goes on the lift in 3 days. I found a buyer for the motor today and received a better offer just moments ago, both with intentions to put the 4.4 in a range rover.
    Last edited by Plattus1000; 07-11-2017 at 12:14 AM.

  18. #93
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    What's that satin look like black coat on those heads?



  19. #94
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    Quote Originally Posted by auaq View Post
    What's that satin look like black coat on those heads?
    It's a graphite dusting. I just called them to ask. Good question though. I thought it was odd that the top of the head used to be shiny albeit varnished with oil and now they are dark grey.

    Now I really like these guys, going that extra step, nice.
    Last edited by Plattus1000; 01-25-2016 at 03:14 PM.

  20. #95
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    I'd like to measure the 4.6 dimensions, as I want to see the differences is clearances between the 4.6 & 4.4. Thanks for asking!
    Looking good, what does the graphite coating do in real world terms?

  21. #96
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    Quote Originally Posted by whiteghost1 View Post
    I'd like to measure the 4.6 dimensions, as I want to see the differences in clearances between the 4.6 & 4.4. Thanks for asking!
    Looking good, what does the graphite coating do in real world terms?
    I was told it prevents corrosion and helps "seat" stuff.

    So I can get eyeball-TDC but without the flywheel from my engine (still in the dd car till this Thursday) it wouldn't be accurate. I'll also need an odd gague to measure that and I'm sure we have one but since he moved to his new place, James is still dealing with boxes of tools and stuff. He hasn't had time to really, fully set up yet.

    I'll get this question answered asap. In the meantime, you could check with the 4.6 guys over at xoutpost. They might have the answers already.

  22. #97
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    This weekend we pull the motor. Before I rip the heart out of my baby, I thought it'd be a good idea to put it on a dyno.



    https://youtu.be/svJY1nFtC6w


    I went to a place called "Drift-office" in Aburn, WA.
    Really cool guys, Bill and Bob.


    They put me in the driver's seat and we did 4 pulls. 2 pulls in 3rd and 2 in 4th.



    Results:
    252 hp at wheels with 274 ftlbs torque
    They said add 20% (for energy lost in the transmission) but at 15% its 289.8hp. Not bad considering the car was rated at 290 originally.
    Last edited by Plattus1000; 07-11-2017 at 12:19 AM.

  23. #98
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    Not bad at all. How many miles?



  24. #99
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    Quote Originally Posted by auaq View Post
    Not bad at all. How many miles?
    Somebody didn't watch the video...

    157k

  25. #100
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    I was staring at the speedometer the whole time ....



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