The engine :
3.2 evo engine + 6 speed gearbox ,55k miles ,one not so carefull owner ! thats why i got it.
I had removed the engine and box from the e36 the day before.
Old engine out :
Dropped it in but didnt realise at the time id need a 5 series sump !
Sump hitting the crossmember :
So new pump was needed as the evo one wont work with the 5 series sump.An m50 one was used.
the 5 series sump i recieved a week later from quarry :
Had to remove this baffle thing to fit it,also the oil pump braket for the evo pump needed to be removed from number 5 main bearing cap. :
Engine in !! :
After that the radiator and pipe mods were done to pipe everything up like fuel pipes , heater and coolant etc
Now the electrics :
Ian Haynes supplied me with full wiring instructions and was very easy to follow.The EWS 2 is all wired in also :
Lots of crimping and soldering later and all was done.
I also decided i didnt like the e36 wiring box so i fitted a e30 4 cylinder cover and crammed all the wiring into it. Looks nice and neat,and factory looking.
The prop was shortened and had the e36 part welded on at reco prop,cost about £100.Also i made my own custom gearbox mount to hold it in there as there isnt one that can be used.
Then the next major and probably the hardest part of this conversion the plenum to servo clearance.Basically there is none ! the standard servo wont fit so i fitted an 1.3 MK2 golf servo but it was still hitting so i removed a 2" long by 1" wide piece out of the corner of the plenum.And it fit ! Only problem now i needed a master cylinder to fit,and be shorter than the e30 one as it would hit the intake boot on the plenum chamber so and audi one was found to fit.It fits straight to the golf servo with no mods.As i will be upgrading to bigger calipers on the front i have fitted a 25mm audi mastercylinder instead of the 23mm,which is same size as the stock e30 one.
Heres a pic :
It fits but the brake lines needed remaking to reach,also note that the intake boot still looks very close and wont fit on.
So I decided to move the servo over on the bulkhead 0.5" to make some clearance.
Re drilled it all and made the servo fit ,half an inch over.Nice one i thought but then the lever on the inside wouldn't connect to the servo.
So i extended it and re-drilled it.
This worked a treat.
I then seen a carbon fibre plenum on ebay! so i had to have it.
I thought it would fit as i had seen an s50 converted e30 on e30.de so i bought it.It didnt fit
£500 wasted.But then i came up with the idea of shortening the trumpets and putting samco hose inbetween, so heres what it looked like :
So nice one back on track i thought but i couldn't fit the MAF sensor in and i was unhappy with the quality of the trumpets so off it came again and i decided to TiG the old plenum up and fit that.
I may try and remake the trumpets in aluminium and ditch the maf sensor so that i can justify the £500 chunk of carbon fiber sat next to me now on my desk,but later .I want to get this on the road now !
I thought now would be a good idea to convert to an e36 steering rack instead of the crappy e30 one so i did this now before the exhaust manifolds are done.
Got a rack off ebay,pipes off Ian Haynes and made the column joint myslef.
Fuel pump needed changing for an evo one.
Its a tight squeeze but it fits.I fitted rubber around it after i took the pic to make it sound quieter.
A couple of the inside of the car :
Heres a couple of pictures of where im up to now which is all done appart from the exhaust :
Heres the clearance at the servo to plenum chamber :
If it hits then i will just solid mount the engine,but i dont think it will.
The exhaust manifolds are being modded now by someone i know,then i will complete the rest of the exhaust system.I have bought an evo back box but its bloody heavy and a bit too big so will need modding to fit so i may not use it yet.
So to sum it up,theres the exhaust to do and then off for the MoT.
I will paint the cam cover the same as i have the plenunm in that wrinkle paint but im waiting until the exhaust manifolds are on so i dont chip the paint !
I also need to re route the oil cooler as its just cable tied to the bottom of the rad for now but i will move it to where iot needs to be when its on the road.
Many thanks to Ian Haynes and all the other people on here who have helped me.
Sorry about the maaaassssive post !
Comments,questions guys and girls,
cheers
andy
, and knowing that a lot of racers etc ditch the MAF on the 3.0s cars, and that people have had success with the plug-in chips on the motronic getting rid of the MAF I thought that might be an easy way out.
LOL,ive taken the alpina stuff of now,except the steering wheel as i really like it,but i may put the momo race back on.
If not is something major! 