M20 to M50 Conversion - Yet again! Please Help. (Longish)

[E30-OBSESSION]

OK, This is crunch time, I have studied many threads regarding this conversion but have read many conflicting things dependant on which route people have taken.

It was always my intention to perform this April, however my hand has now been forced because my head is cracked - this means I have to start this on Saturday.
As with any conversion like this i'm sure it's always easier in theory than in practice, so guys I need some serious advice.

The car in question is a 325i touring, manual 1989 model, the donor car I have is a 1992 E36 325i coupe non-vanos model, I have the whole car so any bits needed from the E36 can be instantly sourced for this purpose.

I have many questions but don't really know where to start

I intend to use the E30 gearbox, as I understand it this can happen if a certain amount is taken from the flywheel, how much needs taking off and from which side? or if I decide to use the E36 gearbox what are the implications of that?

What sump do I need? is it an E34 M50?
What about cooling, which rad can I use?, am I able to retain the viscous fan or will I need to put an electric one on?

What route is needed as regards to the brake servo?, why do you need to change it, purely for clearance issues because of the larger cylinder head?

This I feel is just the start of it, basically i'm hoping for specific answers to my cause, there are many more questions like electrics, heater pipes etc. but this will start the thread and at least get the ball rolling for me.

Your help would be very much appreiciated(sp?)

[eko]

Sump and oil pick up from an E34

Use your radiator or E36 one if not damaged?

Golf mk2 1.3 servo to clear inlet manifold

Dont know about E30 box,i used E34 one which then means you need to change the diff

[E30-OBSESSION]

Many thanks eko for the quick response, a couple more questions.....

Did you use the standard viscous or an electric fan?

Did you have to change the diff just to get the correct ratio or were there other reasons, I intend to use a 3.64 LSD which is currently having new bushes and seals fitted.

You may know, what will need doing to the exhaust manifolds?, can I run the standard exhaust system mated to custom downpipes or may I even have to leave the cats on?, if the brain thinks it's running cat's will it fuel accordingly and run like a pig?

How about the heater pipes, are they theoretically just plug and play?

How difficult is the engine wiring to make happen?

Sorry to batter you all with all these questions but I need to be armed with as much info as possible (pitfalls etc.) before I go ahead and rip the guts out of it.

Any other info i'd be grateful for!

Many thanks again

[DanThe]

You have not been reading the right threads if your asking these questions

Here ya go, have a butchers

http://www.e30zone.net/modules.php?name ... velopments

Dont worry about cats, as long as you have an O2 sensor in the system all will be fine

[eko]

Electric fan,i used a mitsubushi 24v sport thing electric fan,just did a rough measure up on mine,went to the scrap yard,had a mooch and came across this one,very powerfull and think it only cost a fiver!

Ratios in the M50 box are not really compatabale with E30 ratio.
Im currently using a 3.46 diff but this isnt 100% ideal,think a M3 3.25 is best.
You may be ok with your choice of gearbox though?

Manifold mod pics can be found in numerous M50 threads,easier if you look at pics.
Mated up to standard 325 exhaust on mine!

Heater pipes go straight on no problem,although i had to cut half inch off one of the matrix tubes!

Engine wiring depends on year of car,ie pre or post facelift.
This is done by pin numbers,again read M50 post for these answers.