Project: BMW E21
Discussion
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
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
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
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
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.
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.
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.
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.
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.
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.
Yup, I'm looking at the remounting of the existing servos if I need to. Using the S2 setup is my last option in all honesty.
If it doesn't get used, I'll either send it back to you, or if you prefer I'll pass it onto someone who is planning to use it, or if you prefer, sell it with the proceeds going to charity?
Either way, I'll see what's likely to fit first.
If it doesn't get used, I'll either send it back to you, or if you prefer I'll pass it onto someone who is planning to use it, or if you prefer, sell it with the proceeds going to charity?
Either way, I'll see what's likely to fit first.
I've been focusing my efforts on getting the engine bay ready for this weekend, which is when the M20 will hopefully find its new home.
I wanted a fresh OEM sound deadening section, but BMW don't supply them anymore and nobody in the UK was holding any stock, so I resorted to buying some engine bay specific material and making my own.
Spent a while templating it up and cutting it out then covering it with a water resistant fleece.
Then got it fitted with velcro, so I can remove it in the future, should I need to.
Nice delivery of parts and tools arrived too:
Old subframe compared to the new one:
Fitted, with the fresh ARB:
Made a fresh brake line (old one had snapped)
and fitted:
First servo fitted:
All finished:
Few more bits and pieces to be doing over this week, then ready for dropping the engine in on Saturday.
I wanted a fresh OEM sound deadening section, but BMW don't supply them anymore and nobody in the UK was holding any stock, so I resorted to buying some engine bay specific material and making my own.
Spent a while templating it up and cutting it out then covering it with a water resistant fleece.
Then got it fitted with velcro, so I can remove it in the future, should I need to.
Nice delivery of parts and tools arrived too:
Old subframe compared to the new one:
Fitted, with the fresh ARB:
Made a fresh brake line (old one had snapped)
and fitted:
First servo fitted:
All finished:
Few more bits and pieces to be doing over this week, then ready for dropping the engine in on Saturday.
Got some wiring done today.
Some people keep the C101 plug from the E30, but I wasn't too keen on that, I much preferred the setup of having the E30 engine loom wired straight into the E21 fuesbox plug.
So, the existing C101 plug on the E30 engine loom:
E21 fusebox plug:
I followed a guide that listed what needed splicing with what, and got it done. I still need to sort a line out for the tachometer and another for the fuel pump.
I also got an E36 battery distribution box, which collects the power from the battery in the boot and distributes it accordingly to the starter motor, alternator etc.
Made a couple of 'L' brackets up and got the box in the correct place. The battery cable is a really thick gauge, and it required a hole drilling in the boot bulkhead and the loom grommet needed a small slice in it, but it's in now. The box will have the appropriate covers on when it's all done.
Looks OEM enough.
Some people keep the C101 plug from the E30, but I wasn't too keen on that, I much preferred the setup of having the E30 engine loom wired straight into the E21 fuesbox plug.
So, the existing C101 plug on the E30 engine loom:
E21 fusebox plug:
I followed a guide that listed what needed splicing with what, and got it done. I still need to sort a line out for the tachometer and another for the fuel pump.
I also got an E36 battery distribution box, which collects the power from the battery in the boot and distributes it accordingly to the starter motor, alternator etc.
Made a couple of 'L' brackets up and got the box in the correct place. The battery cable is a really thick gauge, and it required a hole drilling in the boot bulkhead and the loom grommet needed a small slice in it, but it's in now. The box will have the appropriate covers on when it's all done.
Looks OEM enough.
More wiring done today.
Battery terminal all connected up:
Tidied up the wires, they'll be wrapped in proper loom tape once I know everything is running.
The spliced loom plugged in too. I fear I've made the new bit too long, as there's a fair bit of wire hanging down when it's plugged in.
Got the fuel pump wired in on a spare fuse in the fuse box, so it's all proper and correct. Need to wire it to the actual pump still though.
Left to do:
Reverse light switch.
Tachometer.
Ignition coil fitted and wired up.
Oil Pressure Switch.
Few plugs left to sort etc.
ECU mounted and plugged in.
Then anything that's left outstanding.
Battery terminal all connected up:
Tidied up the wires, they'll be wrapped in proper loom tape once I know everything is running.
The spliced loom plugged in too. I fear I've made the new bit too long, as there's a fair bit of wire hanging down when it's plugged in.
Got the fuel pump wired in on a spare fuse in the fuse box, so it's all proper and correct. Need to wire it to the actual pump still though.
Left to do:
Reverse light switch.
Tachometer.
Ignition coil fitted and wired up.
Oil Pressure Switch.
Few plugs left to sort etc.
ECU mounted and plugged in.
Then anything that's left outstanding.
Not got any pictorial updates at the moment but progress has been great recently.
Most of the wiring is done, need to do the fuel pump still, got a few questions that need answering but I'm getting there.
Airbox is on, with brackets made. Expansion bottle is fitted, brackets made. Radiator is fitted. Ignition coil is fitted. Wiring loom is in place, and just needs a cut making in the firewall for the ECU to be mounted. Oil pressure switch is wired in. Exhaust downpipes are fitted.
Need to order some bits ready for some work on Friday, hopefully will be turning it over soon.
Most of the wiring is done, need to do the fuel pump still, got a few questions that need answering but I'm getting there.
Airbox is on, with brackets made. Expansion bottle is fitted, brackets made. Radiator is fitted. Ignition coil is fitted. Wiring loom is in place, and just needs a cut making in the firewall for the ECU to be mounted. Oil pressure switch is wired in. Exhaust downpipes are fitted.
Need to order some bits ready for some work on Friday, hopefully will be turning it over soon.
Got a load of work done today, lots of jobs that needed doing.
Radiator mounted:
Coolant bottle mounted:
[url=https://flic.kr/p/n1hqxw]
Airbox mounted, just need some jubilee clips for the rubber boot:
The loom leading to the ECU needs to pass through the firewall somewhere. I've decided to house the ECU in the space under the scuttle panel. It'll be stored in a waterproof case to protect it from moisture. So the I cut a notch in the firewall in front of the heater fans:
Then with the modified scuttle panel fitted:
E30 coil is mounted in the OEM E21 position:
The standard E30 oil lines don't fit on the E21, so I cut them and I will fit rubber oil hoses between the hard ends:
Fitted on the car:
Oil cooler fitted on the car, sat in front of the radiator, I'm hoping the space between the cooler and the radiator will be sufficient to allow for the electric rad fan.
Also got the adapter fitted for the radiator fan temperature switch, put it in the top hose so as to get the correct temperature reading. For some reason the top house mounting point is in such a place that there is no way that it could be done in one single bit of hose, so it has to bend away from the 'stat housing and then back around. As a note, that hideous blue anodized adapter will be painted black. I can't stand for colours like that!
Engine bay is looking very full now. I've got a few bits on order, including the somewhat vital part that is the ignition coil main wire to the distributor. On back order from BMW, so I can only hope that it turns up soon.
I'm "hoping" to start it over Easter weekend, but it all depends if the parts I need arrive in time. Fingers crossed.
Radiator mounted:
Coolant bottle mounted:
[url=https://flic.kr/p/n1hqxw]
Airbox mounted, just need some jubilee clips for the rubber boot:
The loom leading to the ECU needs to pass through the firewall somewhere. I've decided to house the ECU in the space under the scuttle panel. It'll be stored in a waterproof case to protect it from moisture. So the I cut a notch in the firewall in front of the heater fans:
Then with the modified scuttle panel fitted:
E30 coil is mounted in the OEM E21 position:
The standard E30 oil lines don't fit on the E21, so I cut them and I will fit rubber oil hoses between the hard ends:
Fitted on the car:
Oil cooler fitted on the car, sat in front of the radiator, I'm hoping the space between the cooler and the radiator will be sufficient to allow for the electric rad fan.
Also got the adapter fitted for the radiator fan temperature switch, put it in the top hose so as to get the correct temperature reading. For some reason the top house mounting point is in such a place that there is no way that it could be done in one single bit of hose, so it has to bend away from the 'stat housing and then back around. As a note, that hideous blue anodized adapter will be painted black. I can't stand for colours like that!
Engine bay is looking very full now. I've got a few bits on order, including the somewhat vital part that is the ignition coil main wire to the distributor. On back order from BMW, so I can only hope that it turns up soon.
I'm "hoping" to start it over Easter weekend, but it all depends if the parts I need arrive in time. Fingers crossed.
So today was the first attempted start of the M20. Key word being "attempted".
First off, there was no starter motor, turned out I'd missed a ground strap, and the switched live on the SM had come undone, so that was fixed, but the SM tried to crank as soon as I connected the battery, that was because the switched live and permanent live (from the battery) were too close, and were arcing across. Some insulation tape and relocation of the wires sorted that.
With the engine now cranking, it was time to check the fuel pump, which seemed to be okay (apart from me forgetting to fit the fuse that I had wired in!).
So the engine was getting fuel and crank, but at this point we identified that there was no spark. The coil was getting the required 12v, and the resistance between post 1 (-) and 15 (+) was the correct 0.5 OHMs, the king post was the correct 5000 OHMs, and the coil to dizzy lead was the correct 2000 OHMs, so all seemed fine there.
Anyway, I started looking at sensors and the possibility of the ECU not providing spark. CPS at the front of the engine was fine, but I noticed that the gearbox that came with the engine had two sensors in the bell housing. One is a speed sensor (irrelevant to me) and the other is a CPS reference sensor (or so I believe) The gearbox that is on my engine is an E21 gearbox and is required as it has the necessary provision for the mechanical speedo drive. That E21 gearbox does not have a provision for the CPS reference sensor, which means the ECU isn't getting a signal that it thinks it should be, and thus is not providing me with a spark.
So my options are:
- Run the E30 gearbox and use a GPS speedo drive + other mods.
- Keep the E21 gearbox and upgrade my Motronic 1.0 to a Motronic 1.3.
I'll probably be doing the latter because the gearbox swap requires the engine to come back out, and also means bodging the speedo. The Motronic 1.3 swap would be better because the M1.3 doesn't require the CPS reference signal, it uses a single sensor on the crank at the front of the engine. There is a cost issue with the swap though, as I'd need a fair few bits, but it's still probably the best option for me.
I also noticed that my ICV seemed to be on permanently, suggesting it was somehow on a permanent live. I'll see if that is still the case when I swap over to M1.3 and if so, address it then.
So in all, it seems my work/mods are fine, and the car would have started today had I known about the CPS ref sensor, but these things happen I guess.
Off to eBay I go to cost it up...
First off, there was no starter motor, turned out I'd missed a ground strap, and the switched live on the SM had come undone, so that was fixed, but the SM tried to crank as soon as I connected the battery, that was because the switched live and permanent live (from the battery) were too close, and were arcing across. Some insulation tape and relocation of the wires sorted that.
With the engine now cranking, it was time to check the fuel pump, which seemed to be okay (apart from me forgetting to fit the fuse that I had wired in!).
So the engine was getting fuel and crank, but at this point we identified that there was no spark. The coil was getting the required 12v, and the resistance between post 1 (-) and 15 (+) was the correct 0.5 OHMs, the king post was the correct 5000 OHMs, and the coil to dizzy lead was the correct 2000 OHMs, so all seemed fine there.
Anyway, I started looking at sensors and the possibility of the ECU not providing spark. CPS at the front of the engine was fine, but I noticed that the gearbox that came with the engine had two sensors in the bell housing. One is a speed sensor (irrelevant to me) and the other is a CPS reference sensor (or so I believe) The gearbox that is on my engine is an E21 gearbox and is required as it has the necessary provision for the mechanical speedo drive. That E21 gearbox does not have a provision for the CPS reference sensor, which means the ECU isn't getting a signal that it thinks it should be, and thus is not providing me with a spark.
So my options are:
- Run the E30 gearbox and use a GPS speedo drive + other mods.
- Keep the E21 gearbox and upgrade my Motronic 1.0 to a Motronic 1.3.
I'll probably be doing the latter because the gearbox swap requires the engine to come back out, and also means bodging the speedo. The Motronic 1.3 swap would be better because the M1.3 doesn't require the CPS reference signal, it uses a single sensor on the crank at the front of the engine. There is a cost issue with the swap though, as I'd need a fair few bits, but it's still probably the best option for me.
I also noticed that my ICV seemed to be on permanently, suggesting it was somehow on a permanent live. I'll see if that is still the case when I swap over to M1.3 and if so, address it then.
So in all, it seems my work/mods are fine, and the car would have started today had I known about the CPS ref sensor, but these things happen I guess.
Off to eBay I go to cost it up...
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