Project: BMW E21

[melvster]

Congratulations on the mag feature. Fantastic build which deserves the recognition.

[eddiethekid]

This weekend I removed the engine, with the help of Jon, Christopher, Joey and Oli. Was a dream to work on, not a single nut or bolt stuck, even the manifold and exhaust came off without the slightest of resistance, very impressed.

The Saturday was a day of removing parts; prop, exhaust, loom, cooling system etc. Then on the Sunday, we set about removing the engine and gearbox.

Jon and I grabbed some photos along the way:













Then got the car wired up to a Garrett



Need to start work on the M20 (which is now on the engine stand) over the next few weeks. Want to get the engine bay tidied up too, including paint.

Exciting times

[e21Mark]

Obviously, being an earlier pre-facelift e21, you've got dual brake servos like the 2002 etc. Are they likely to get in the way of dropping in the m20/2.5? If they do, I am pretty sure I have a later servo set-up which I'd be happy to give you for free. Hopefully it won't be an issue though.

Nice one on the mag feature. It's a nice addition to the service history and they are certainly some nice photos.

[eddiethekid]

Yeah that servo setup might come in handy mate, thanks very much.

I'll drop you a message if it's looking like the M20 is going to come into contact with my existing setup.

[e21Mark]

No problem. The other alternative is that you replace your OE servos with a remote dual circuit servo, like the one I'm using as an upgrade on my car. The benefit of that, is that you can lose all the convoluted linkage BMW used to go with RHD. Just let me know either way.

[eddiethekid]

So today Jon and I worked on the M20, getting it stripped down and cleaned up. We lost some time when we had to move the engine out onto the drive to get it under the gazebo to avoid the rain, but other than that, everything went well.

Started off like this:





Manifold off:



Inlet removed and timing cover off:



Timing belt removed:



Waterpump removed and cleaned up, new tensioner fitted and timing belt replaced:



All cleaned up and ready for the painting and refitting of the ancillaries/brackets/etc:



Thoroughly enjoyable day working with a mate, on an engine. Perfect

[g3org3y]

Great project.

[eddiethekid]

So today I picked up the subframe and ARB from the powdercoaters. Very impressed, the quality is excellent and they're well priced too.





Also got some fresh ball joint boots fitted on the control arms, ready for fitting on the car.



Took a wire wheel to the shims that sit either side of the control arm bushes. They were crusty as hell, but they came up really well, before and after:



Then got a load of stuff painted up in black and silver, so I'll get some photos of those bits tomorrow once they're dry.

All good

[eddiethekid]

Today was a very productive one.

Got the fuel tanks out ready to install the new fuel return line:



Wasn't too much of a nightmare as I had expected. Drained the tanks and left them out to air any fumes out. New fuel pump is here and ready to be fitted once I've got a fuel level sender from an E30.

Underside of the car (the area hidden by the tanks) is in very good condition:



I also got the engine bay stripped, all the braking system is now out, and the steering rack is off and ready to be spruced up.



All stripped and ready for paint.



Really excited and motivated about the project at the moment, it seems every week the progress is flying. Also another weekend of thanks to the lads that helped, this time Rhys and once again Jon giving me a much needed help.

Over this week I'll assemble the new subframe and ARB, get the M20 rocker cover painted up and ready. Need to order a few bits for the M20 as well (inlet manifold gaskets and rear crank seal).

Plenty more to come soon.

[e21Mark]

Looks like it could be a tight fit for your dual servo set up as I feared?

[eddiethekid]

Yeah quite possibly.

I'm hoping the servos sit low enough that they might clear the inlet on the M20, but I'm not sure.

Did you say you had a single servo setup that might work?

[e21Mark]

Yeah, I have an 0E set-up like the one in the picture. I imagine they swapped to that arrangement because of the lack of room? Mail me your address and I'll donate it to the cause.

[eddiethekid]

Got the subframe and ARB assembled this evening:





Then it snowed, which was annoying.

More to be done on Thursday and over the weekend.

[e21Mark]

Just dug out the servo, mount and linkage for you. I'll get it boxed up sent so that you can clean it up.

[eddiethekid]

Marvellous!

Thanks very much Mark, really kind of you.

[eddiethekid]

Got some work done on the car today.

Petrol tanks painted, and then a good thick coat of underseal applied.



I then prepped the inlet manifold and rocker cover, under the site lamps which produce at least the required 16°c to make the paint wrinkle correctly.





Then applied the paint and let the lamps do their work. The results are fantastic and I'm very impressed. I'll sand up some of the details and it should complete the look really well.







I also got my fuel return line fitted. The engine bay is pretty much ready for paint too.

[e21Mark]

Looks great. I used a cardboard box 'oven' and a hairdrier heat source, when I used crinkle finish paint.

Servo will bee there for the weekend.

[eddiethekid]

Got the rocker cover finished and fitted today:





Picking up a manifold tomorrow, and should be making some progress tomorrow afternoon.

[e21Mark]

Servo was collected today.

[eddiethekid]

Got a load done today,

New fuel pump and fuel level sender fitted:



Did some work on the engine too.

New inlet manifold gaskets:



Inlet manifold fitted, and BMW logo and details sanded up:



Accessory belt fitted, with PAS pump deleted:



All the surface rust cleaned up in the engine bay. Battery tray has been removed too, ready for the battery to be relocated to the boot. All sanded areas etch primed:



Started stripping down the steering rack and cleaning up the individual components.