E36 328i Touring. When it breaks, upgrade it...

E36 328i Touring. When it breaks, upgrade it...

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carpetsoiler

Original Poster:

1,958 posts

165 months

Monday 12th October 2015
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Ben- thanks a lot smile it's been a hell of a learning curve, but I've decided after a lot of deliberation that I'd gladly do it again.

Ian- was good to meet you, and hopefully I'll be putting her up the strip next year... she's running better and better.

In other news, had some bodywork done and the car doesn't look like a fking shed any more. This is good times indeed. New 24lb injectors are on their merry way from the States, and then she's in for mapping. We've worked out that the greedy cow doesn't misfire/knock/retard timing as long as she's fed the finest-quality super unleaded. Definitely seems to prefer Shell Fast and the Furious Nitro VPower Willywaver, or whatever it's known as these days.

More updates to come... she's still far from finished.

geeks

9,188 posts

139 months

Monday 12th October 2015
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I love this car and continue to be jealous smile

rossi1

773 posts

202 months

Tuesday 5th April 2016
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Hi Mate, great build !! i know its been a while since an update but im also looking at the 3.5" maf and larger injector upgrade.
Is it worth it?

carpetsoiler

Original Poster:

1,958 posts

165 months

Tuesday 15th November 2016
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Well, it's been a while.

It's certainly been a busy year (?) or so since I last did a proper update, too... and it will continue to be a while, as I need to get my photos from my phone onto Photobucket!!

The 3.1 has been a fraught project. It's been one of those things that, when it's worked, it's been unstoppable. I genuinely feel that the 3.1 is my favourite engine in an E36 chassis. After working out more foibles, and changing more parts, I felt like we were finally getting somewhere. Between January and May, we had a fully functioning, weapon of an estate. Everything meshed together well. In April, she went to the 'Ring and was a thoroughly enjoyable car.

In early June, tragedy struck. A rad hose popped off the thermostat housing on a gentle drive to drop off an MX5 soft-top. When I restarted the engine, the oil light was on, and a gentle tick-tick-tick that got steadily louder proved that all my lifters were draining all their oil at an alarming rate. She was nursed onto the back of a trailer, unceremoniously discarded on my driveway, and she is still sat there following some interesting tests with an oil pressure gauge, and some replacement parts.

I haven't lost heart, at all. I have just been very, very busy. Firstly, I spent a lot of time developing a set of cams for the M50/M52 engines. This came from a frustration at the lack of affordable aftermarket options available to us in the UK. I am happy to say that I am now working my way through the orders for my 3rd batch of 5 cams- we started selling them in April, and had a brief hiatus following some manufacturer hitches. They gained 14bhp and 25lb/ft just by dropping them into our development 328i (from 210bhp and 180lb/ft to 224bhp and 205lb/ft), and following mapping it made a heady 250bhp and 230lb/ft. We're not finished tuning that car either. I have also been designing other products and getting my fingers stuck in other pies.

Now... back to the good lady that this thread centres around. The engine is dead, and will be pulled out and revived. However, it will no longer live on in this car. In January, I happened upon a handsomely priced Alpina B3 3.3 lump- the 280bhp S52B33 lump, which is effectively a bored out and superstroked M50B25. That is being built to my spec. I've had some interesting gremlins- such as Alpina wanting £1,000 for the piston rings (yes, you read that right). However, now one of my major projects is firmly on the way, I predict that the new engine will be built and ready by December. I am aiming for 300bhp and 270lb/ft. This should be feasible. I will be using a set of bespoke cams that my engineer and I are designing at this current time, a better intake manifold, and the full S50 exhaust system. Seeing as Alpina managed to reach 280bhp with daggy exhaust manifolds, a set of fairly crap cams and a halfway house intake manifold (the Alpina one is a bit of a compromise between an M52 and an M50 manifold), I feel that 300bhp is not unreasonable.

She also has a Kaaz 2-way locking diff to go in, I'm completing a rear Brembo conversion to match the E31 840Ci Sport front Brembos, the existing Recaro Speeds have been oiked out and will be replaced with Recaro Pole Positions or Bride Vios IIIs, and I've finally got her on a set of lovely BBS RC304s with Nankang NS2Rs.

Watch this space- the rest of 2016 and 2017 will be an exciting one. A few pictures, just because. Oh- and there's a new addition to the stable. A lovely Santorini Blue 328i Sport, which the more eagle-eyed among you (especially the resident E36 perverts) will recognise from here. smile



My friend took Claudia out for his first ever lap of Nürburgring, in the snow. In a 260+bhp RWD car with no traction control. Balls the size of lemons.





Loved these three shots- nearly getting air coming out of Adenau bridge, I think. I'm not entirely sure where this was on the track, but that was a seriously fking fun lap.



So was this one, judging by my passenger's face.



The new arrival smile she's my daily until Claudia rises again.

More pictures of oily bits to come. If any of you are on Facebook, my page is JustDeutsch- there's a lot more detail about cams/projects on there.

helix402

7,861 posts

182 months

Tuesday 15th November 2016
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The new engine sounds good.

JakeT

5,428 posts

120 months

Tuesday 15th November 2016
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I was wondering what had happened to this car a while ago to see you hadn't posted an update in ages. Looks like it's on track for greatness! I'm surprised you haven't gone 100% mad and tried to make an S38 work for some M5esque madness.

anonymous-user

54 months

Tuesday 15th November 2016
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I've been really enjoying this thread, and then you start talking about developing the Alpina 3.3 a bit more... now, very interested in the cams and airbox, for my 3.3. I know the S52 manifold fits the head, I think it might foul the steering on my E46 but I guess is perfect on your E36.

Keep the updates coming!

carpetsoiler

Original Poster:

1,958 posts

165 months

Thursday 17th November 2016
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helix402 said:
The new engine sounds good.
It'll be quite something. Piston rings turned up today- upgraded to S50 ones. The bearings are in the post. I've secured an M3 Evo sump/oil pump for it to avoid the issues I had last time.

JakeT said:
I was wondering what had happened to this car a while ago to see you hadn't posted an update in ages. Looks like it's on track for greatness! I'm surprised you haven't gone 100% mad and tried to make an S38 work for some M5esque madness.
There came a time when I was so busy actually doing stuff to it that I didn't have time to update the thread, and just sort of... forgot! I will provide some more pics shortly!!! There's a lot been done!

Polynesian said:
I've been really enjoying this thread, and then you start talking about developing the Alpina 3.3 a bit more... now, very interested in the cams and airbox, for my 3.3. I know the S52 manifold fits the head, I think it might foul the steering on my E46 but I guess is perfect on your E36.

Keep the updates coming!
Would it interest you to learn that my engineer and I are developing specific 3.3 cams? What we've noticed is that Alpina actually used the standard S52B32 exhaust cam- which is actually pretty pony, about 240º duration and 9.7mm lift from memory. The intake cam is a custom grind but I've not worked out what the specs are- one of my mechanics is currently running around with my set of Alpina cams in his car and won't give them back. biggrin however, I'm aiming to maximise the 3.3 to its full potential. S50 exhaust manifolds have been made to fit an E46, but it was a real bugger- I know one person who's done it. I can enquire on your behalf..? wink

anonymous-user

54 months

Thursday 17th November 2016
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carpetsoiler said:
Would it interest you to learn that my engineer and I are developing specific 3.3 cams? What we've noticed is that Alpina actually used the standard S52B32 exhaust cam- which is actually pretty pony, about 240º duration and 9.7mm lift from memory. The intake cam is a custom grind but I've not worked out what the specs are- one of my mechanics is currently running around with my set of Alpina cams in his car and won't give them back. biggrin however, I'm aiming to maximise the 3.3 to its full potential. S50 exhaust manifolds have been made to fit an E46, but it was a real bugger- I know one person who's done it. I can enquire on your behalf..? wink
Please!!! I know it makes no difference day to day, it's already a great engine, blah, blah. But jesus, taking it to 286 and stopping there, 300 is just around the corner, Alpina. Yes, they obliged with the 3.4, but I rather like the sound of camming an Alpina engine, whacking on some beautiful and impossibly wriggly exhaust tubes, maybe an airbox and going for a nice round 300.

Grateful for any inputs on throwing more money at my aging BMW.

and, good on you, this is going to be an awesome Touring. We all know they are the best body shape :-)

carpetsoiler

Original Poster:

1,958 posts

165 months

Thursday 17th November 2016
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Polynesian said:
carpetsoiler said:
Would it interest you to learn that my engineer and I are developing specific 3.3 cams? What we've noticed is that Alpina actually used the standard S52B32 exhaust cam- which is actually pretty pony, about 240º duration and 9.7mm lift from memory. The intake cam is a custom grind but I've not worked out what the specs are- one of my mechanics is currently running around with my set of Alpina cams in his car and won't give them back. biggrin however, I'm aiming to maximise the 3.3 to its full potential. S50 exhaust manifolds have been made to fit an E46, but it was a real bugger- I know one person who's done it. I can enquire on your behalf..? wink
Please!!! I know it makes no difference day to day, it's already a great engine, blah, blah. But jesus, taking it to 286 and stopping there, 300 is just around the corner, Alpina. Yes, they obliged with the 3.4, but I rather like the sound of camming an Alpina engine, whacking on some beautiful and impossibly wriggly exhaust tubes, maybe an airbox and going for a nice round 300.

Grateful for any inputs on throwing more money at my aging BMW.

and, good on you, this is going to be an awesome Touring. We all know they are the best body shape :-)
280bhp! They couldn't even crack 286. bds. biggrin

Well basically... the 3.4 isn't actually a 3.4. It's got 3,348cc of fury, but they had to differentiate it somehow. It's got bigger runners on the intake manifold, an 87mm bore (but same crank), and some seriously hairy cams. I went out in one the other week and (with all due respect), it's the first E46 I've ever desperately wanted!

I've enquired about the S50s on your E46. Don't be surprised if it's megabucks though. No one really likes taking that job on when there's an E36 involved, let alone an E46. Plus point here being that your engine is basically a big M50.

Now... where's my Photobucket app on my phone... st's about to get real.

carpetsoiler

Original Poster:

1,958 posts

165 months

Thursday 17th November 2016
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Photobucket app downloaded and installed.

Many hundreds of photos incoming.

2016 started with a leaky sump that needed sorting.



Always leave your phone number on your exhaust manifolds- very important when your car's upside down in a field and people need to check you're alright.



Surgery.



3.8kg UUC flywheel just peeking through at the back there.



New gasket, lots of st scraped off it.



One of many things that's been keeping me distracted- my little company (me) has been developing a plug and play gauge kit for the M50/M52 engined E36s.



The idea is that it'll replace either the climate controls (they relocate to the sunglasses cubby with relative ease), or the stereo fascia goes for cars that are a bit more track-orientated. I don't really want to entertain gauges down by the gearstick- they're not exactly in your eyeline when driving.



Voltage, oil temp, oil pressure, and an option to switch around with an accurate water temp as well.



Distribution block that screws into where the idiot light sensor goes on the back of the oil filter housing. Again, totally plug and play, and you retain the idiot light.



Time finally came to replace the shagged E36 M3 rad I had under the bonnet. Another £240 later...





Something else that's been keeping me occupied in the shed. Cams! This was from the first batch I had done. Currently taking orders for my third batch, and we're designing 3.1 stroker-specific cams at the time of writing. smile



Sitting pretty, and working at this time...



This was a good day. Fitting the first ever set of our cams!



The loyal test subject- a very fun 328 saloon.



Important to have correct tools- timing, torque wrench, socket set, and brass balls.



Freshly installed.



All back together.



More to follow...

carpetsoiler

Original Poster:

1,958 posts

165 months

Thursday 17th November 2016
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We're currently at April.

Claudia decided to prove that she could really chuck some awesome curveballs at me. 14 days before Nürburgring, her first go as a stroker, and she decided that losing a rear subframe bush and possibly tearing out some mounts was a great idea.

NO IT IS NOT.



Couldn't really do this in my road.



Off it comes.



Mounts absolutely fine. So I made some reinforcing plates...



Cleaned and ground back...



Holding it in place...



Buzinga. Welded on.



While I was there... replaced the anti roll bars with fking massive Schnitzer items, rear subframe bushes are now Powerflex purples, and I also welded reinforcement plates into where the ARB mounts to the chassis. I made the nuts for the ARB carriers captive at the same time with a few little tacks.





Also replaced the pad retaining pins on the Brembos, cleaned stuff up, new droplinks at the front and another massive ARB...





Decided to change the cam caps as they were incorrect.



And the cam trays...



All back together...



...didn't fking time it properly and bent 4 valves. tt.



INTERJECTION: Nürburgring trip: T minus 4 days and counting at this point.

Onwards.



Fresh head.



Got fed up and put ARP head bolts in, so fking tired of swapping heads and spending out on new head bolts every few months...



Clean.



4 days later...











What a trip. We found out that she can do 160mph and keep pulling off the clocks, that clutches aren't fun to bleed in the snow, and that she can outpace a brand new Focus RS driven by a timid person.



Somewhere around this time, started building another project... just an M52B28 rebuild.











Disaster struck... rad hose popped off the thermostat housing. When I restarted... oil light was on and a faint ticking got steadily louder (not a spun bearing, don't worry). It was all the oil draining out of my lifters. Fml.



To be continued...

carpetsoiler

Original Poster:

1,958 posts

165 months

Wednesday 23rd November 2016
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So. Where were we? Ah yes... she died. Brilliant.

Now, back in January of this year, I got linked to something on eBay that I couldn't really turn down... an Alpina 3.3 engine from the B3 3.3 E46, in bits. It had a cracked head, the cams, and the block with internals.

I didn't really care about the head, as they use a standard 1 738 400 head that's been ported/polished by Alpina. This is work that can be recreated if need be. I was most interested in the block, which uses unique Mahle pistons that are a) quite small and b) lightweight, as a result. It also uses a simply massive stroke- 94mm- and is pretty much the biggest you can fit in an M5x-based engine.

Nerd time... it's actually based on the US M3 engine, which is an S52B32. This has 86.4mm bore, and a theoretical 92mm stroke. It uses the same crank as an M54B30, which basically means the stroker done with an M50B25 block and M54B30 crank is a small-bore version of a US M3 engine.

Alpina seemingly bought every single piece of backstock from BMW, and set about using them in their cars. The first ones were the E39 B10 3.2 and the E36 B3 3.2, which were for all intents and purposes just a standard US M3 engine with an Alpina intake manifold and a remap. The cams are the same profile as the ones you got in the S52B32 engine. Power output: 261bhp and 240lb/ft.

Then came the E39 B10 3.3 and the E46 B3 3.3, which is the engine you see here. They put in their own crank, which has a 94mm stroke, they commissioned some pistons from Mahle, and they also upgraded the intake cam. The exhaust cam remained as per the US M3 engine, and I think the rods were retained as well. The head was ported/polished accordingly. Power output: 276bhp and 247lb/ft.

The final incarnation was the 3.4 lump that was used in the E46 B3 3.4S and the Alpina Roadster S. This was the pinnacle of the M5x engine, really. It was bored out to 87mm- really the very highest it can be bored to. The crank was left the same. It used quite a thick head gasket, from memory. Even wilder cams. A much bigger intake manifold. It wasn't actually a 3.4- it tipped the scales at 3,348cc- but they wanted to differentiate it from the 3.3 in name. Power output: 300bhp and 267lb/ft.

I've always had this craving to build a 333i, but with the 3.3 Alpina lump fetching a hefty £2,000+ by itself, it was always destined to be a pipe dream. Until this popped up.

Now... pictures...

Another of my amazing clean environments to pull an engine to bits in.



Essentials. Buzz gun, pot to throw all the bits in!



Crank wheel off...



Sump off...



Oil pump off...



Oily bits.



Still good crosshatching on the bores.



Weird black burnt mark- as this engine came to me with a very, very cracked head, guessing this is something to do with it.



Strange water staining. I'll let the engine shop deal with that. Can't feel it with your thumbnail, so that's good.



Got home for dinner that night with some essentials.



Lovely pistons/rods.



Bit crusty but not the worst I've seen!





And then came the debacle...

Edited by carpetsoiler on Wednesday 23 November 18:26

carpetsoiler

Original Poster:

1,958 posts

165 months

Wednesday 23rd November 2016
quotequote all
So. Piston rings.

These I'm used to setting me back about £90 for a set of 6 for the 84mm M54 pistons... S50 ones for the M3 will usually run a bit higher, about £150 a set, give or take.

I called BMW and asked for a quote for some 3.3 piston rings, as they're unique to those pistons (allegedly).

They got in touch a day later.



Ha, I don't fking think so.

So I went about it the old fashioned way... ordered myself a set of digital Verniers off eBay, and got to measuring.





Top ring... 1.2mm



Middle napier ring... 1.5mm



Oil scraper ring... 2mm



So with the sizes discovered, I went on the rampage and set about asking various companies for some help sourcing some that weren't a thousand fking pounds for 24 bits of slender metal.

I was chatting to someone else who has an M54B30 turbo build. He asked about the viability of using S50B32 pistons in his engine... 'no mate, they're the wrong bore'... but... not for me.

The S52B33 and S50B32 share an 86.4mm bore.

So I went to the corner of my bedroom with the S50 pistons in it (everyone has that corner in their room, right?), and did some measuring...



That's the S50 piston rings on the B33 pistons.



Problem solved. S50B32 rings- same measurements, made for blocks the same material, with a higher rev limit. Same styles of ring, same thickness. What more could you want?

Further remedy to stop any further oil pump issues.



More to follow when Photobucket stops being a dick.

helix402

7,861 posts

182 months

Wednesday 23rd November 2016
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Great update. Making me miss my M52tu, (got an M57 now).

carpetsoiler

Original Poster:

1,958 posts

165 months

Wednesday 23rd November 2016
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helix402 said:
Great update. Making me miss my M52tu, (got an M57 now).
I ran an M57 from December to September. Brilliant engine (530d Sport Touring). They benefit from a few things. Is yours auto/manual? Got a few tips/tricks for you, if it's auto...

helix402

7,861 posts

182 months

Wednesday 23rd November 2016
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It's an auto with a reader's cars thread.

carpetsoiler

Original Poster:

1,958 posts

165 months

Wednesday 23rd November 2016
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helix402 said:


It's an auto with a reader's cars thread.
Change the box fluid if you've not done so already. Replace your vac lines. Swirl flap delete. Decat pipe. Map it. Enjoy it. smile

If there's any work you desperately need carrying out... I don't mind working on M57s. biggrin

EDIT: read through your stuff, I think you're just fine. tongue out

Edited by carpetsoiler on Thursday 24th November 00:38

carpetsoiler

Original Poster:

1,958 posts

165 months

Thursday 24th November 2016
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Right... carrying on where we left off.

I really don't want a repeat of what happened to the 3.1. Really, really don't want that. At all.

So we've gone belt-and-braces this time round!

Firstly, the wired pump nut, pictured above.

Secondly, an S50B32 oil pump with twin pickup, and the sump, which is baffled, etc.



Then we got to stripping the rest of the engine to bits.

Crank looks in utterly exceptional condition- no scoring/wear on any of the journals, anywhere. I couldn't believe it- I bought the engine mileage unknown, but clearly it's not that high in the mileage stakes.













I'm going to get some comparisons in design/weight between this crank, and the M50B25 crank & M54B30 crank I happen to have knocking around at my container. It will also be degreased/cleaned before it's reinserted, obviously...

This is what near as dammit £1,000 looks like. Or, as Alpina would call it, 'a full set of S52B33 piston rings'. Clockwise from top right- ARP main stud kit, ARP head stud kit, NE S50B32 piston rings, King Racing rod bearings, King Racing main bearings, finishing on ARP rod bolts.









Block taken to my local shot blaster. He'll be covering *everything* with tape and then blasting the old manky paint off it. It's going a nice, rich gloss black, with a couple of my company's stencils painted on there too. As soon as it's blasted, it goes straight in for honing and cleaning- make sure there's no media in any of the oil galleys.





Back to the pistons... time to clean them up! Before...







Comparison between one that's getting there and an unclean one...





And all done. smile









Saved the best shot 'til last... piston porn...



Hnnnnngggggghhhhh!!

More to follow in a couple of weeks, I'd imagine. smile

JordanTurbo

937 posts

141 months

Thursday 24th November 2016
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Looking good. thumbup

Been just over a year since I last got stuck into an engine build (the 4.6 RV8 for my Disco) and this is giving me withdrawal symptoms.

I really fancy building an M50B30 non-vanos turbo for my e36. But have a serious lack of any spare time at the moment.