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M3 Evo 3.2 1997 (HACKAR) Part 2

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Here's is a link to Part 1
http://bimmersport.co.nz/topic/43521-m3-evo-32-1997-hackar/

So here's a reminder of what I'm up to Dec 2014

Clutch Gearbox components.jpg

M3 Air Clutch Job.jpg
My baby up in the garage on my Christmas present to myself (QuickJack 3500)
Motor supported.jpg
Motor supported

At this point the jobs not done, but thanks to Google and BMW forums thing are moving along.
I'm not in a hurry but here's the progress so far.
The gearbox is out, Clutch and Flywheel as well.

Old Clutch.jpg

Perfect timing, while I'm at it I'll replace all the gear shifter bushes as well.

New V Old clutch plate.jpg

Can you guess what these are. Big thanks to Rockwell for saving me so close to Christmas

Gearbox mount broke.jpg

Bolt layout and sizes, I spent 3hrs with torch on head, mirror in mouth lying on back towards the rear of the car trying to get the top left bolt out (miss info from net on size)

The 14mm at 9 o'clock was pain 5 shops and I couldn't find a wobble head to work. Had to really lower the engine even more. 

Bell housing Bolts.jpg

Looking up her skirt

Under belly.jpg

Secondary air pump oil leak (gone now)

Emission Non-return valve.jpg

Rod bearings replaced and ARP bolts installed, the old shells had approx 100k on them but looked fine.

100kms rod bearings.jpg

Dismantled the oil pump, no sign off wear. :) 

Don't forget to pack it full with vaseline so it's primed if you don't it may not pick up the oil in the sump. Remove fuel pump fuse or remove coil pack so the car won't fire/start. 

Starting the car for the first time was the most terrifying part, turn the car over for 5-7 seconds approx 6-10 times and breath again :) when you see the oil pressure get to a safe level.(remembering I have an oil pressure gauge installed)   

Oil Pump.jpg

Lower chain tensioner wear, decided while it's open I'll replace it. while waiting for the new part to arrive.

oil chain tensioner.jpg

I grabbed front and rear reinforcement plate kits I had and welded them in.

Front Crossmember Reinforcement (Medium).jpg

Below the old and the new, as well as the tool I made for removing and installing the clip shown. A piece of flat bar, shaped as you see to remove, slotted on top to install second picture down.

On the net the DIYs say that the front cover has to be removed. I did mine from underneath, it is tight up there. 

Here's the trick the metal springs/lever is actually two levers separate them and have a look. Put it back together, but.

Leave the low one out 60% but so it's still under the other.  Install the bracket on the pin and manipulate/slide the upper lever into place.  

Once the upper lever is in place you just have to push the second lever up and it's guided into place by the first lever...............  The will make sense I promise 

Oil Pump Tensioner.jpg

Clip holder.jpg

Feb 2015

Dual pickup fuel pumps, along the lines of the Pumpkin setup. 

This pump sit in the passenger side tank with the engine return feeding into the filter. This pump then feeds fuel to the engine pickup pump sump. 

Passager side connection (Small).jpg

FFT430 Fuel tube installed (Small).jpg

Finished product, does it work as of 2017 I haven't had a chance to see. Just some notes after multiple attempts at trying to get the fuel gauge to work constantly I gave up.

It works most of the time, but now I also use the trip meter as a back up.    

Duel pump system Completed (Small).jpg

Brought a 20 ton press

Control arms (Small).jpg

New Ball joints for my front control arm, they deserve them after 170km

Control arms 2 (Small).jpg

 

Nov 2015

235 x 40 x 17 R888  (god I love the smell of new rubber)

20151106_165224 (Medium).jpg

Jan 2016

Made myself a String Alignment Box,  why New Tie Rods

New Tie rod ends (Small).jpg

Cut lengths (Small).jpg

Connectors (Small).jpg

Alignment Arms Rear (Medium).jpg

Alignment Arms Front (Medium).jpg

Digital C/C Gauge w AccuLevel and Quick Set LW Adapter

$_1.jpg

Alignment Arms  (Medium).jpg

Bottom line ..... if I had a pit it would be great, my car is to low for me to adjust the toe without jacking. Easier just to take it to an Alignment shop.

 

Jun 2016

After my weak performances at Hampton Downs in Jan & Feb driver training, I gave up trying to diagnose the problem.

Booked into Gavin's he's the man, he did his magic and now we've cracked the 200 (ye baby)

2017 update got a chance to get back on HD now because of conditions no lap records were set but, I ran out of 3rd gear leading up to the big sweeper and changed into 4th only a quarter of the way up the hill on the front straight. But interestingly still only managed 193km at end of the front straight taken from GPS (speedo read 200km)

BMW E36 M3 1997 Jun 2016 Dyno (Medium).jpg

Package from Ground Control, upgraded to adjustable Race inserts and a pair of adjustable rear control arms. 

New Valved shocks and rear adjustable arms GC  .jpg

Now you know why, both the front and rear passenger side shocks were leaking

leaking shock (Medium).jpg

During the changeover I found this a small crack, I believe it is from me adjusting the camber and with the camber plate sitting on that weld it gave way.

I've ground down the weld, but I wasn't allowed to do the repair welding as the expert didn't trust me.

Underside crack.jpg

I found my old tower reinforcement plates and modified them to allow for full camber adjustment. Why didnt do this previously I don't know 

Top side fix.jpg

Mod M3 reinforcement.jpg

Aug 2017

RallyRoad front strut bar and rear end Black Powerflex bushes.

strut brace ploy rears (Medium).jpg

RallyRoad strut bar installed not the 5 min job I thought. Needed to order the special nuts and had to trim them as they sat proud. (sorry the part # for the nuts is missing forum change platforms and lost most of my writeups)

RallyRoad Strut Bar (Medium).jpg

Rear end removed, time to install the Powerflex Black Bushes

Rear end removed (Medium).jpg

Rear end cleaned (Medium).jpg

Tried the drilling out.............smelly and messy

First bush (Medium).jpg

Went back to the 20 ton press, gave up the first time because of some of the fun angles and packing I tried seemed dangerous.

Second time was just as scary, I hid round the corner a few times. 

Bush Press (Medium).jpgBushes removed (Medium).jpg

When fitting the GC adjustable control arms, I needed to adjust both the lower bush and the control arm opening so it didn't bind.

20160823_102521.jpg 20160823_111406.jpg

Replaced my boot loom, don't remember what I had in the write up sorry.

Thanks to Dave (M3AN) as I said to you didn't need to provide me with a new loom but it is appreciated. 

Boot wire loom (Medium).jpg

Sep 2016

I know it's not Christmas or did it just come early. But these were listed on Trademe for the second time this time I had to have them.

Recaro CS Sportsters full leather, heat........................

Recaros in (Medium).jpgRecaro out in (1) (Medium).jpg

Weight saving only 12kgs total

 

vader recaro2 (Medium).jpg

As these are not standard BMW E36 M3 seats here in NZ you need to get any modification Certified, including my rear adjustable control arms.

The first certifier I went to was a total num nuts. His requirements, required me sending numerous emails to recaro germany, spending days fabbing up slider releases (which I got to work)

But I was still 15mm short of exist distance on the drivers side and germany wasn't helping with the other request removal of airbags.

In the end I rang Wellington spoke to LVVTA, then went to another certifier all the above was a waste of time and stress. If it doesn't sound right just call Wellington it's worth it.

Just for the record no 95% of aftermarket seat mounts/sliders are not certified, which means you cannot mount your safety belts to them.

All modifications Certified, I got my little piece of paper and cert plaque riveted in my engine bay  

 

Below give you an idea of what's required, you will need to go to LVV site download the H template and instructions to work out your individual seat belt receiver location and height.  

Lower/Upper Plates were from Auckland Seat Belts, in Glenfield. They sell them as a kit.

Tunnel double plate.jpg

Driverside plate stork.jpg

Needed a spacer

stork spacer.jpg

H points marked

stork behind carpet.jpg

Airbag occupancy light removal: no dash light, air bags are always active.

Drivers side activator.jpg

passager activator.jpg

 

March 2017

During regular maintenance back 2016, I came across some oil in my Plenum.

So for Christmas I got a ECS oil catch can

So decided to remove the plenum, check the throttle butterflies and install the ECS oil catch.

(You may also notice the Power pulleys from ECS as well, but they manufactured for TMS which don't fit Euros. Well the power steering does and is now fitted.)  

ECS catchcan.jpg

On inspection 1-2-3 were dirty but 4-5-6 butterflies were a real mess. Throttle body cleaner and toothbrush to the rescue. The vanish in 4-5-6 was impossible to remove.  

Throttle  body dirt.jpg

Throttle body oil.jpg

Location of catch can

catchcan location.jpg

 I cleaned the IRV and oil separator, replacing the hose # 5 as it was very mushy. As you can see I have left the OS in place and have just added the catch can inline.

Routing the hoses was fun setting the hose clips, so they didn't rub or impede putting the plenum back on took a couple of tries. 

hoses route.jpg

This was a resolute of plastic fatigue :ph34r: not a hose clip for a coolant hose on the back of the plenum and me having too much spinach.

Many thanks to Aronn for sending up his spare. Means I'm driving my baby 7 days early.  

Broken funnel.jpg

Installed, will update after a few Kms, late April update I have not removed the lower canister, but after approx 700ks and a driver training day there is no sign of oil on the dipstick.

20170320_182014 (Medium).jpg

At the last monthly coffee meet, I mentioned to the guys that even though I loved the sound of my car. I was driving like a nanny because it drew to much attention.

Here's my first attempt, start with the tail pipe got some silencer packing cut it to fit the inside made a cage and slipped it in. I couldn't get the cage to fold nicely around the ends so just cut out a panel and fitted it in.

Result: did take the edge of the exhaust tone. UPDATE..... April 2017 driver training, blow the cage and packing out of the tail pipe :)

Tail pipe (Medium).jpg

Scorpion Exhaust (Medium).jpg

Next idea, now I know that Scorpion exhausts are guaranteed for life but mines dated 23-99 so I thought maybe the silencer/sound packing had maybe disintegrated.

I did some research ordered  3 x Acousta-Fil Boa bags from GB @ $18 each NZ, $100 with delivery.(once again NZ company did themselves out of a sale $69 a bag)

A bag of 35mm stainless steel plugs and borrowed a mini camera.

Accousta_BOA (Medium).jpg

Here's where I'm going in

Rear of box (Medium) (Small).jpghole drilled (Medium) (Small).jpg

I couldn't believe how much packing I got out, took a couple of hours. I had to make up some hook tools. So much for the silencer packing being disintegrated :) 

sound dunage (Medium).jpg

Used all three bags, inserted the plug with some high temperature silicone.  

exhaust pluged (Medium).jpg

June

Was looking at CAE & RTD shifters online a month ago. Then blow me down a RTD was put up for sale on here... :D Couldn't help myself.

593c89ed04151_RTDDSSR.thumb.jpg.f431930e747b2b72d1b02e3934da1d4d.jpg593c8a300a299_Console.thumb.jpg.88809f983f61da8834a8ae5bd8599f51.jpg

Spent some time trying to contact the manufacturer. So I could buy the RTD DSSR ,spoke with John he recommended just going with UUC.

Installing was a PITA only because I know better than most (right) and installed both pieces with the exhaust and drive shaft still in place.  

It's tight under there and the tolerances are also amazing. I needed to remove the gear selector input shaft joint and sand the bush slightly to get fit the DSSR to fit.

Reinstalled the DSSR, then spent a couple of hours trying to get the DSSR and RTD lower arm to match up for the connecting pin I could get it within 1.5mm

I ended up making a temp pin approx 0.5 smaller with the leading edge chamfered. :)  Got it back together went for a drive but got the first base location wrong couldn't get into 2,4,6th.

The bolt on the hazard light end of the base only just catches the base plate. The OEM knob sits slightly skewed to the left. 

Time for a drive up around the bays, interesting totally different from standard very precise you need to shift quickly when I shifted at a leisurely pace I'd get lost :unsure: 

Drivers training in 2 weeks need to work on the muscle memory till then  

593c8a343dfbe_RTDINSTALLED.thumb.jpg.a7f6e9a22cbe260c69cb9c55826620e4.jpg

 

Driver training :( after a dozen emergency braking exercises :D I once again lost 2nd, 4th and 6th gear. On inspection I cannot tell if the units base has moved.

I'm guessing as the fixing locations are maxed out, once things hot up it moves outside of useable tolerance. 

July

Keeping to my philosophy of there must be an easier way............... e.g. not removing exhaust, driveshaft etc to remove shifter

5957194f5762d_homemadetools.thumb.jpg.2dae0dfbec561dd7dc474def4516e2b7.jpg595719bca5b33_alignmentmarks.thumb.jpg.158a1fd1f1ab2b940f9d5c38e12df823.jpg

Tools I adapted to reach nuts from inside the cabin. With the base in place.         Marks on tunnel not centred misaligned offset to the left

 

595ef7955ca88_modbase1(Medium).thumb.jpg.a3d9547ed3dc655738b482fe9d9992f7.jpg595ef2023fb5b_20170701_121849(Medium)(Small).thumb.jpg.6cbd53a51b12bd0a429b25ec3f881b22.jpg

I forgot to take photos, one day.

So the plan was as above extend both top slots and angle them slightly to centre base, just slotted them as above.

Didn't extend the sides but extended the rear nose (now a closed in slot) and have had washers and nut bases welded together to reinforce the tunnel sheet metal. Upsized the nuts and bolts to from 6mm to 8mm. Also made reassembly from inside the cabin a breeze. I have only cruised around Devo, but changing gear, finding gears is much easier. But won't know if the reason I did this works till some spirited driving is done.   (see update below)

Dec 2017

Coolant flush and new thermostat.

29th Dec driver training.

Good stuff first, RTD shifter is superb. I love it .

As always 1st session was just a shake down, second session pushed a little harder 1.19:5 but then 

sad to say only lasted 1/4 of the 3rd session before this happened

5a5fa70b2947b_fanbroken(800x600)(640x480).jpg.fea2f0ee5dd103a2f5c6eb21924ae5e6.jpg5a5fa7102b7a0_damagedradiator(800x600)(640x480).jpg.15ebc6faf4d33849dc35aed8aff6743a.jpg

Damaged my radiator, rad shroud, fan and oil cooler lines. Waiting now on parts

These arrived today Vibra-Technics BMW362MX 

5a5e891172a10_VTenginemounts(Small).jpg.4b6f0e348c2402232ca290cd09b1b5ba.jpg 5a5e866fc2a31_cookedenginemount(Small).jpg.8bc98c3666aeeaa75eaed67ffe6ad057.jpg

Removed Poly Engine mounts

5a613318c2dc8_PolyEngMounts(2)(Small).jpg.0000dea153ba518a06ce06433bc4dad7.jpg5a61343144fc5_PolyEngMounts(1)(Small).jpg.9d89c275ce68ddb8caebadd589b85741.jpg

Well a picture or two are worth a thousand words: No heat shield to speak of (top right), the poor old passengers side bolt & plate have moved under the strain.

5a653c0dcce54_NewRadshroudfan(Small).jpg.1d8d99b6e8a4ebf1e79264d55b4c15fa.jpg 5a67dc78c6665_HeatShield(Small)(2).jpg.1654ed545c451a6a4e3f1b8d1ab611cc.jpg

New parts in waiting, over the top heat shield for drivers side engine mount. Think I'm going to have to strap it in place.

Feb 2018

Installed finally, engine mounts, uprated heat shield drivers side, oil cooler pipes(4wk wait) radiator including mounts, vent pipe, fan and shroud.

As a precaution after the failure of the engine mounts, I loosened the gearbox cross member and gearbox mounts and re-adjusted them.

May

New Crankshaft sensor

 

 

 

Edited by sweetm3
updated
  • Like 8

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Looking decent so far. Where did you get them QuickJacks from? How much weight can they hold?

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Looking decent so far. Where did you get them QuickJacks from? How much weight can they hold?

How long to raise car up? 10 seconds

How much $ depends where you buy

Where from? Online :) Sulco nz

how heavy are the units? Postage weight total approx 60kgs,

Load limit 3500lbs

Cheers

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How long to raise car up? 10 seconds

How much $ depends where you buy

Where from? Online :) Sulco nz

how heavy are the units? Postage weight total approx 60kgs,

Load limit 3500lbs

Cheers

Ah sweet. I use to work for Sulco tools. Maybe ill get a discount, maybe not. Could definitely use this.

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quick up date, things are progressing (see first post)

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Good work Mark, top effort for a one man job!

ETA for back on the road?

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Love the home made engine support "bar".

Edited by vtgts300kw

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Good work Mark, top effort for a one man job!

ETA for back on the road?

ETA who knows :blink: I don't (month maybe)

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Thanks Mark for the privilege of driving your car today, I really enjoyed that. Given how many 'track' upgrades you've done I'm impressed with how drivable it remains, it's still 100% a daily although we both noted the comparative serenity of my cabin!

Your clutch/flywheel combo is impressive, it's amazing how these lumpy engines benefit from the light flywheel and I don't think you need to worry about how much you had to shave off, it's lovely and brings the car to life under 3500 rpm. And the idle clatter is marginal at worst, most of it is masked by the exhaust anyway.

Definitely the most 'sorted' e36 M3 I've had the pleasure to drive and you should be proud that you've done most of it yourself.

Now you just need to get those doors, steering and VANOS sorted right... ;)

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Cheers Dave

It's amazing how over time you can get a customed to things, slowly lossing your eye sight your hearing etc (you can tell I'm old :) ).

After driving your bady around, I was reminded of how refined a BMW E36 M3 can be........ jesus mines a beast.....but I love it.

Now get some race pads, rubber and lets go have some fun at the track mate ;)

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^ on my priority list!

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Updated

a few photos

DIY on oil pump chain tensioner replacement in-stu

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You're right Sam seeing I'll most probably only use it a couple of times. But there are a couple of things I want to try out with my setup and seeing I'm replacing my tie rods why not

I'll still be taking the car to the shop after to see how accurate my setup is.

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updated above page 1

Edited by sweetm3

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Keen to see how pump goes as need to do mine, will have a chat sunday

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Fuel pump idea is clever.

I like the thinking outside the box.

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I like your work, but IMO you have the hardest to follow way of posting, by adding it to the end of the first post. It reads better if its just added inline in the conversation.

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Keen to see how pump goes as need to do mine, will have a chat sunday

Should know around a 1/3 tank, fingers crossed

Fuel pump idea is clever.

I like the thinking outside the box.

Internets a wonderful thing

I like your work, but IMO you have the hardest to follow way of posting, by adding it to the end of the first post. It reads better if its just added inline in the conversation.

I was hoping that keeping it in one place would make it easier to find and easier to keep track of updates. Glad you like what I've done much appreciated

Mark

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I personally like the layout of the thread. I've got a wheel alignment setup that looks almost exactly the same. I had some nylon pads for going under the tyres during use

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To level my garge floor I had packers under 3 of the 4 wheels. Both front wheels were packed and the packers moved free on the floor so no binding. But with my car being low I had to jack it up to adjust. If I do it again I think the solution would be to make 4 platforms for the wheels and car to sit on............. but I not sure if I can be bothered

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Soooo, how did the new fuel setup go?

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Soooo, how did the new fuel setup go?

Post update,

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Post update,

How low could you go before surge?

I found with only the standard pump it was ok at 1/2 full, but not really keen to try any lower.

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