BMW M3 Coupe S85B50 V10

[sergey_e30]

Considering that our vanos pump was inoperative, it was decided to remove the vanos. This decision was prompted, firstly, by the fact that buying a used pump is a lottery, and their prices are not cheap. A new pump costs about more than 1,500 euros, moreover, it is not known in what condition the vanos themselves are, and their cost is also not small. And secondly, as I wrote in one of the previous parts, according to the experience of other S85 owners, even more power can be removed without them.

 

Split gears were made from the original drives of the vanos with the ability to mechanically adjust the position of the camshafts.

 

 

We put the shafts along the valve overlaps.

 

 

Vanos covers were made on a milling machine

 

 

 

 

There were a lot of shavings))).

 

 

The result is the following installation kit:

 

[sergey_e30]

The removal of the vanos, which I wrote about in the previous part, brought another very big plus: the work on installing the radiator and its pipes was much easier due to the fact that the engine in the places of the vanos became much shorter.

 

I had to think a lot about the radiator. It was immediately decided to make a custom radiator. There were two main problems:

 

• Firstly, for the base, it was necessary to select from catalogs the largest radiator that fits into the E30 in size

 

• Secondly, the original radiator from S85 consists of 2 separate radiators and it was necessary to make a decision whether to repeat this scheme or make one radiator for 2 heads.

 

We did not understand exactly why the original S85 radiator was divided into 2 radiators, (like to reduce the pressure), but in order to avoid problems with fluid circulation, it was decided to repeat this scheme.

 

A radiator from an M3 E46 was chosen as the basis; it almost ideally fit in size and was available in Moscow.

 

 

 

 

It was before the new year and an order from Europe would have to wait at least a month. The original side plastic tanks were removed from the radiator

 

 

 

and welded aluminum.

 

 

We made the bends for the pipes and welded them.

 

 

The hoses from the S85 were shortened, tubes were inserted in the middle, and they fit perfectly into place.

 

 

Bearbeitet: 21. April 2021 von sergey_e30

[GaragenWerke]

Great progress man!!! 

[sergey_e30]

Next, we moved on to making the engine wiring.

 

 

 

It was decided to preserve the factory look under the hood as much as possible, so the wiring for the ABIT was remade from the original S85 wiring. Several days of work and the initial version of the wiring was ready. Also, changes were made to the algorithm of the operation of some parts, for example, the engine cooling fan at 1st and 2nd speed will be turned on by a signal from ABIT, the air conditioner pump clutch will also be activated from the engine control unit with the ability to turn off when the gas pedal is pressed to the maximum to increase power ...

 

 

 

To obtain maximum information about the operation of the engine, a broadband oxygen sensor and an EGT sensor (exhaust gas temperature sensor) were installed in each of the engine halves.

 

Also, an oil temperature and pressure sensor was installed in the oil filter housing.

 

Installed a coolant temperature sensor.

 

We installed M50 throttle position sensors, and we also had to make adapters for them.

[sergey_e30]

Choosing the clutch was easy. On my turbo m50 at one time there was a SPEC Stage 3+ clutch from an S38 engine with an M5, designed for a moment up to 525Nm.

 

 

Up to 550 hp, it showed itself very well, and it was possible to drive it like a normal one. Therefore, I decided to buy the same for the S85.

 

Now it remains to make a flywheel for it. The engine was bought without a flywheel, since I did not want to use the original damper flywheel, the price for it was not small, and I thought that it would not be difficult to find a dead flywheel from an S85 for reasonable money. Unfortunately, this was not the case. A couple of weeks of searching and I was already ready to buy a good flywheel on Ebay for 500 Euro. I wrote to the engine seller asking if he had sold the flywheel from my engine, it turned out that he had sold it, but promised to try to quickly find another one. And the truth is, a few days later the flywheel turned out to be with me, and completely free of charge, at the expense of the killed vanos pump. The condition of the flywheel was so-so, but I only needed a crown with a reference disc from it.

 

Next, a new clutch basket 240mm from the M30 was purchased, from which the clamping part was taken. And a large piece of aluminum was bought to make the flywheel.

 

 

The manufacturing process has begun.

 

 

 

 

 

After a few days, the flywheel was ready.

 

 

 

 

And it is installed on the engine, which was removed from the car to install new inserts, timing parts, etc. new spare parts came to refresh it.

 

 

The clutch also fell without problems.

 

[Avdei]

Absolutely insane work! Keep up with the great work

[Stauber]

"WOW"

[sergey_e30]

Maybe someone can help me with my project?

 

Still looking for:

 

I need a few original details from M3 E30 for my project:

Front left bumper bracket M3 E30

Front a-pillar trim M3 E30

 

I have attached a photo of these parts, if not clear. A friend of mine in Munich can buy them for me if there are difficulties with shipping to Russia

 

 

 

 

[sergey_e30]

Those who have read the previous parts will remember that the vanos pump was almost completely destroyed.

 

 

But it was not possible to simply throw it out of this engine, since the main oil pump is driven through it and therefore it was necessary to bring it back to life so that it could function simply as a transmission mechanism.

 

The pump housing was restored on the machine, the seizures were removed.

 

 

 

 

We made the inside and assembled it.

 

 

 

 

Now oil is supplied to it only for its lubrication, the outputs are closed, a new gear was installed.

 

[sergey_e30]

By the end of work on the flywheel, new spare parts for a small refresh of the S85 just arrived.

 

 

 

The engine was removed, the lower part was disassembled

 

 

installed new inserts, timing drive, sprockets and oil pump chains, other little things and assembled for installation.

 

 

 

In one of the previous parts, I wrote that the oil filter housing was installed in front of the driver's side, and the oil pump outlets on the S85 from the passenger side. We made pipes connecting them and fixed them on the engine.

 

 

 

 

 

It was planned to connect the power steering pump with the tank with hoses, but the engine turned out to be so close to the body that the supply and return hoses did not crawl through, it was necessary to weld the tubes.

 

 

 

[sergey_e30]

It's time to do the exhaust. The catalysts were sawed off from the exhaust manifolds, they are definitely not needed, and they do not fit.

 

 

 

It was a pleasant surprise that the pipe turned out to be exactly 63mm

 

 

 

 

we welded a V-Band to it, but I thought that it was thicker and the diameter would have to be reduced, because two 76x pipes would be very difficult to pull under the bottom. The collectors fit perfectly, the clearance to the body.

 

 

 

 

 

In Europe I bought a resonator with 2 63 inputs and 2 63 outputs. I bought a bunch of 63 pipes, bends, V-Bands. All this was welded.

 

 

The rear muffler was ordered by Superspint, but due to the COVID, the manufacturing time began to tend to infinity, so the rear muffler can was temporarily purchased, a replica Magnaflow, and all this was installed on the car.

 

Finished all sorts of little things necessary for the start-up. We installed a temporary tank in the form of a canister and a remote fuel pump. Filled with oils, antifreeze.

 

Everything is ready for the first engine start. We are waiting for the customizer of the control unit to start and first set up

[sergey_e30]

So, everything is ready for the first launch. Of course, there were some small mistakes, they re-pinned a couple of connectors on the wiring and the engine started working !!!

 

https://youtu.be/bOxRtfIPjwk

 

At first there was a small knock of hydraulic compensators, which is not surprising after almost a year of inactivity, I even climbed to see the price of new ones, almost had time to faint, but after a couple of minutes the knock disappeared.

 

https://youtu.be/gnuyNfbCHZ8

 

It responds perfectly to gas !!! Doesn't smoke, at all !!!

 

https://youtu.be/Z97RfGpMs0E

 

https://youtu.be/aMUSf5gXQVg

 

We are all very happy, we need to finish the brakes, wiring, assemble the body and run it first on the road, and then to the dynamometer to find out how much power we got and whether we managed to reach the factory performance.

[sergey_e30]

After launch, for a while, nothing particularly interesting happened. We picked up the front end a little and, to the great joy, the hood closed without any problems.

 

 

 

We made air intakes from the air filters, sawing off the native headlight shields. In the photo, the shields are old and dirty, they were used for fitting, in the final version it will be all new.

 

Left:

 

 

 

 

Right:

 

 

 

 

 

We adjusted the wiring shields, it turned out well, it gradually becomes beautiful under the hood)))

 

 

 

We fixed the engine control units to the brackets from the turbodiesel, where there are also two engine control units

 

 

 

Almost everything is ready for tuning the engine on the road

[sergey_e30]

Even during the first installation of the engine layout, it became clear that there was no place for a vacuum brake booster on the engine shield. There was an option to move it to the left headlight, but then you would have to put a zero-point instead of the filter housing and all the beauty and symmetry under the hood would be lost, and in any case it is not a fact that there will be enough space for the rods. A study of the S85 swaps has shown that it is mainly a tandem pedal assembly with cylinders in the cabin. Was ordered by Willwood pedal assembly

 

 

And brake cylinders to it

 

 

While waiting for the ordered pedal assembly, we started installing the front calipers. The main problem was that once upon a time I bought 3-piece HARTGE rims (they were produced specifically for the M3 E30 and M5 E28) and I really wanted to use them on this car. It was not possible to supply 4-piston calipers with these discs, so we settled on single-piston calipers with relatively small 325mm compound brake discs. After long adjustments, we still managed to establish all this.

 

 

Several offices in the world make ready-made adapters for installing this pedal assembly in the E30

 

 

It was easier to buy it, but since we have slightly changed the position of the steering column and it is not a fact that a ready-made adapter would fit, and we didn’t want to wait for its delivery, it was decided to make it ourselves. After a couple of days, the adapter was ready.

 

The brakes are installed, the first ride took place. And at the first braking, it became clear that it was impossible to drive like that. I don't know how they ride with these sports pedals abroad, maybe they are very strong there, of course you can stop with them, for sports it is probably normal, but there is no need to talk about some kind of comfort when braking. We still need to install a brake booster! (((

[Tobi200]

Fuck me sideways!  Nice work , mate.

 

I always asked myself why Russia is not known for outstanding cars,motorbikes instead of fighterplanes and tanks etc.

 

You are out there to change that impression !

 

Can not wait to see the finished job.

[sergey_e30]

Another big problem with all S85 swaps in the E30 is the sway bar installation. The sway bar does not fit into its original place behind the engine beam, the large engine sump interferes. It also cannot be placed below the engine sump, because then it will practically lie on the ground.

 

And then we came up with the idea to use the sway bar from the all-wheel drive E30, where it is installed in front of the engine beam. They tried it on - it seems to fit. Brackets were made, by analogy with how it was done on the E36.

 

 

 

In the photo, the sway bar struts are attached to the levers, as on a regular E30. In the final version, they will be attached to the front shock tower, both on the M3 and on the iX.

 

The sway bar passes between the two parts of the engine sump, there is enough space for it, it does not touch it for anything, and it turned out to be higher in level than the sump and beam, and so the small ground clearance did not decrease.

 

 

[sergey_e30]

After the first exit and an attempt to drive into another garage, it became clear that driving with such an exhaust was not very comfortable. The middle part of the exhaust system touches high speed bumps, and it turned out to be entered into the garage only by placing boards under the wheels. It touches mainly the left side, the right side is slightly higher due to the fact that the original muffler passes there and there is a stamp in the body. I didn't want to reduce the diameter of the pipes, so we decided to use an oval pipe in the lowest places. Of course, it is much more difficult to adjust it, but it gives a gain of 2 centimeters with the same flow section, its height is 42 mm, versus 63 mm for a round one.

 

 

 

 

There is also a Supersprint muffler arrived

 

 

We decided to install it too, using oval pipes in the back. After the first fitting of the Supersprint muffler, it became clear that classic suspensions with elastic bands would not work, because the distance to the body and to the rear bumper is very small and when rocking, the muffler will definitely hammer on all this. It was decided to rigidly fix it to the body, and weld 2 more corrugations into the track.

 

 

 

 

This is how she looks on the car, the photo is not the best

 

[sergey_e30]

The rear brakes were chosen for a long time. The diameter of the brake discs was about 310-320mm to match the front. Because single-piston calipers are installed in front of the rear, they also decided to install single-piston calipers. The choice fell on the brakes from the M3 E36. The diameter of the brake discs is 312mm. Used calipers in excellent condition were bought pretty quickly. The letter /// M is cast on them))), a trifle but nice.

 

 

We also bought new brake discs, pads, shields, all on the handbrake.

 

The calipers were installed pretty quickly, the adapter turned out to be quite simple.

 

 

But with the handbrake I had to suffer pretty much. To attach the brake shield, a special plate had to be grinded.

 

 

But in the end everything fell fine, the handbrake works without problems.

 

 

 

 

 

 

[GaragenWerke]

looks great, good idea!

[sergey_e30]

After the first not very successful exit attempt, it became clear that driving without a brake booster would be very difficult.

 

We considered several options:

• transfer of the vacuum cleaner to the left front headlight

• installation of a hydraulic booster of brakes

• installation of an electric brake booster.

 

As a result, we stopped at the device of brakes on the principle of clutch, the rod of the vacuum cleaner will squeeze the clutch slave cylinder, more precisely 2 cylinders for reliability. Here is a photo of the first sample of this scheme)))

 

 

 

 

A test drive showed that this scheme is quite viable, braking practically does not differ from braking with a conventional vacuum brake booster.

 

They decided to place this system in the trunk, removing the additional tank. The vacuum will be created by an electric vacuum pump, the vacuum will be controlled by ABIT, turning on the pump when the pressure rises and turning it off when decreasing. So that the pump does not constantly turn on, a small receiver was added. We welded brackets for all this.

 

 

 

 

[sergey_e30]

And now it's time to go to the dynamometer. We loaded onto a tow truck and arrived fairly quickly, without traffic jams.

 

 

Unfortunately, immediately after the start of the tuning, a problem arose, the oil hose from the engine to the oil filter housing cracked, it was temporary, they thought it would be fine for now, then they wanted to put another hose and squeeze it out normally, but it still could not stand it, most likely due to for the high oil pressure in the S85 - about 6.5bar at high revs. Unfortunately, it was impossible to quickly change this hose.

 

It was not possible to set up everything that they wanted to the end, pouring oil on the dynamometer and adding new to the engine, made a couple of measurements, up to 6700 (blue on the graph) and 7200 (red on the graph) rpm not at the worst corners. But even with this result - 459 l / s at 7200 rpm, they are quite satisfied. A thousand more revolutions in stock, plus there is a large margin in tuning. I think it will turn out to reach the result of 520-530 hp. at maximum speed (8250).

 

 

Now the car is waiting for a complete disassembly to a bare body, painting and reassembly. Next time we will go to the stand after the final assembly.