Project twin e34's + X5 4.6is manual swap

[e46v12 477]

So after some time to think, I've decided to do a build thread about my new daily projects or how i came about it.

So I went on the hunt for a E34 sedan as i love the shape. Managed to score the 540i sedan off joKer here on bimmersport.

Wasn't in the prettiest of shape but fixable. 

So on the hunt for parts to fix up the sedan and I see this comment on a trade me ad. Seller saying wheels were off a e34 540i touring and he was looking at selling that one day.

I hit him up and he's keen to sell. Nice I'm thinking to myself i have a complete car to strip parts from!

So long story short I pick up the touring and it is is such mint condition apart from sitting for 3 years. it would be an utter shame to wreck this beast.

So this is where i am now with a daily E34 540i sedan and rare E34 540i touring that i plan to 

New Plans

#̶1̶ ̶c̶o̶n̶v̶e̶r̶t̶ ̶t̶o̶ ̶m̶a̶n̶u̶a̶l̶     #1   Daily E34 sedan - swap to m60b44 and convert to manual

#̶2̶ ̶d̶o̶ ̶a̶ ̶m̶6̶0̶b̶4̶4̶ ̶s̶w̶a̶p̶   #2   Sunday driver E34 touring leave auto and m60b40 add supercharger

So currently both cars are running. 

Sedan just a general clean, got bonnet painted and fitted new from bumper.

The touring had a bit of work to get it going mainly a new fuel pump, drain old fuel, new oil, dry out the carpet and a good scrub.

Here are some picture of before and after of how both vehicles looked.

 

 

 

after pictures 

 

 

enjoy team.

Edited May 14, 2018 by e46v12

[KwS 2429]

Gosh, both of those cars cleaned up really well. Keen to see how this goes.

[Jacko 2158]

Are there two Jackos?.. Or did I buy and sell an E34 with being aware? 

[e46v12 477]

They did clean up well Kevin and apologizes Chris, joker was user name.

[e46v12 477]

So had a fun productive weekend. 

Started Friday morning noticed the sedan was a bit lumpy on start up and knew something wasn't right. got a few opinions and we think something has slipped or broken inside the head causing one of the valves to not open so this will be a job for Anzac day.

Saturday got up nice and early at 3am for a nice long day trip to Auckland, picked up some 18inch Style 135 for the wagon looking at repainting/powder coating them white? ( opinions welcome on colour)

Did a bit of wheeling and dealing with the final outcome of getting a 5 speed zf box out a diesel e46 330d more than capable of handling the torque or the v8. Also got the little nitty bits like drive shafts ,slave, shifter and x member thanks to Raymond from Motorsport rental and parts.

Managed to squeeze a visit to pick apart in Avondale, thanks for the heads up scott aka palazzo.

got a few little bits missing on the sedan e.g ash tray, front chrome grill, tow hook covers and a couple clips.

happy with how the day went but man what a drive, was a zombie by the time I got home.

 

   

 

I have the diesel box next to the getrag 560g to give a comparison between the two, diesel box is pretty beefy.

So need some advice if anyone has experienced this.

The wagon had been sitting for 3 years so i think the tyres may have flat spots, while driving particularly around 80kmh the whole car would start shaking like crazy, so I changed the sedan wheels over with the wagon and it helped alot but still get the shakes and also happens during braking around the 80-100kmh.

Any one know what could be the cause?

Thanks Team  

 

Edited April 23, 2018 by e46v12

[dirtydoogle 383]

Buggered control arm bushings would be what I'd check 

Nice projects!

[e46v12 477]

Thanks Doug,

will either replace them or to be honest look at replacing all suspension/steering  parts , just be on the staff side.

[kiwi535 538]

On 4/23/2018 at 2:46 PM, e46v12 said:

The wagon had been sitting for 3 years so i think the tyres may have flat spots, while driving particularly around 80kmh the whole car would start shaking like crazy, so I changed the sedan wheels over with the wagon and it helped alot but still get the shakes and also happens during braking around the 80-100kmh.

Any one know what could be the cause?

Thanks Team  

 

yes control arm bushings get e34 m5 ones or e32 750 to replace.Its an E34 "thing"

Edited April 25, 2018 by kiwi535
remove excess uneeded original post

[Eagle 1678]

In my E34\E32 experience its usually non perfect wheels, tyre balance or the need for hubcentric rings?. Worn control arms tend to exaggerate things but wont typically cause crazy shakes alone. 

[e46v12 477]

Thanks for the heads up Paul and Jared i defiantly think the wheels had a lot to do with it. 

Will look in to the control arm bushes too.

So spent yesterday investigating the odd problem i was getting with the sedan and it was lucky for me nothing serious at all.

Cylinder #2 had a loose plug that i assume was allowing pressure to come through the head, making that popping sound. As for the odd sound exhaust note found that cylinder #5 had a dead coil. 

So swapped all the plugs over from the wagon (as its done less kms) onto the sedan. tighten the spark plug up and runs as it should now.

Also got started on stripping the paint off the mags too.

hopefully ready for powder coaters next week.

[kiwi535 538]

On 4/25/2018 at 5:45 PM, Eagle said:

In my E34\E32 experience its usually non perfect wheels, tyre balance or the need for hubcentric rings?. Worn control arms tend to exaggerate things but wont typically cause crazy shakes alone. 

not arguing but my e34 developed a wicked shake over a short period of time .new arms&bushes solved it instantly.Nothing else changed in that time

[e46v12 477]

spent the weekend plastic dipping the wheels and dechroming the window trim to black.

Let me know what you think team.

Sorry about the one sh*t picture

 

[e46v12 477]

Hey Team

So did another big one dayer on Saturday.

Drive started at 2am in the morning and didn't end till 8pm that night.

But good day as i purchased more goodies for the projects. 

Went to pick a part 1st in Avondale and scored some bumper bracket, always breaking these bits.

Then onto HellBM finally nice to meet Ray, awesome bloke. Purchased the manual pedal box off him, also showed me around the work shop and his secret stash of projects. Man he's some awesome project going on. SO JEALOUS!

Then onto Brent at BM world he had the big ticket item that was the main reason for the trip. Purchased the 4.4lt non vanos m62 off him, also manual shifter surround, both in black and tan colour. Clutch line and a tuned chip that has a m62 tune done by gavin on it, hopefully this will help it run smoother for a bit till i get it tuned properly. He also threw in a free ash tray.

So next few weekends will be dismantling the motor and swapping heads, here the fun begins  

Oh and a change of plans now.

Im going to keep the touring as standard auto, as its such a low mileage motor be a shame to hack it up.

so im going to convert the sedan to manual now as it will be my daily and i'd rather have a stick than auto as a daily and auto as a cruiser. 

 

 

Edited May 7, 2018 by e46v12

[e46v12 477]

Oh and thanks for the goodies Brent

Legend

[e46v12 477]

Hey Team 

Had some time this morning before work, so got stuck into the motor and started stripping it down. 

Also had to purchase a set of e torx socket set and the best $10 Dollars i ever spent on an extendable magnet pen! man what a life saver that was today.

Few pic of the dismantle sorry pix heavy.

Tomorrow attacking the Jesus bolt.

Edited May 8, 2018 by e46v12

[zero 1162]

Great project.

How many km's on all three engines?

And how will you adapt the 330d gearbox to fit the back of the engine?

 

BTW using the earliest m60 inlet manifold (there were four different ones for the m60/m62) is a good cheap mod.

[e46v12 477]

Hi Nathan

The touring motor has done 190,000kms

sedan 290,000kms

and the m62 above around 200,000kms from what i was told.

Looking at the adapter kit from PMC which comes which plate, custom flywheel and clutch kit.

Thanks for the tip on the manifold.

Can i ask what this mod would help with Nathan?

 

[zero 1162]

The runners are longer and wider and have trumpets so it flows more air.

The later manifolds were quite restrictive.

[e46v12 477]

So ITBs? do you know what year they came out of? might have to go look for some.

 

[e46v12 477]

Sorry just had a quick google and see what you mean about the trumpets

[BM WORLD 1286]

in think your getting mixed up with the later vanos 4.4 v8 has a different manifold ,more restrictive , made for more low end torque .

this one has same part number from dec 1991 to sept 1998

http://bmwfans.info/parts-catalog/E39-Sedan/Europe/540i-M62/R-A/nov1996/browse/engine/intake_manifold_system/#1729528_1

[zero 1162]

2 hours ago, BM WORLD said:

in think your getting mixed up with the later vanos 4.4 v8 has a different manifold ,more restrictive , made for more low end torque .

this one has same part number from dec 1991 to sept 1998

http://bmwfans.info/parts-catalog/E39-Sedan/Europe/540i-M62/R-A/nov1996/browse/engine/intake_manifold_system/#1729528_1

There are four different inlet manifolds available.

There were two different ones for the m60b40, and can be distinguished by how many fuel rail mounts they have.

There were also two different ones for the m62b44; one for the early m62b44, and one for the m62b44tu.

 

The early m60 one with the 4 fuel rail mounts is the one you want. The later m60 with the 5 fuel rail mounts is definitely different internally but has the same part number as the early one which is why it can get confusing.

 

[e46v12 477]

Hey Nathan 

Just did some more reading up on the manifold topic and its quite interesting.

The early b40 have the trumpets then later squared off ones, then round ones on b44 non vanos then smaller over all on the b44tu .

people also talked about the wedge butter fly in throttle body in the b40 model and flat plate in later b44.

Great thing is i have both models so will check and put up pics, 

So hope to have the trumpet intake and flat plate throttle set up.

You learn something new everyday.

Thanks Nathan,

 

Edited May 9, 2018 by e46v12

[zero 1162]

No problem. The runners are bigger on the earlier manifolds too.

I have a non vanos b44, but I got a manifold from the early m60 from the wreckers for pretty cheap.

[e46v12 477]

So was thinking last night and have mentioned i will be keeping the touring factory but would like abit more grunt as it is alot heavier than the sedan and you do notice it in the power department. 

SO what you guys think of this

its a m60b44 with a jag xjr eaton m112 supercharger set up modded to fit. looks so clean and meant to fit in.