How to build a 120i e87

[Captain_Stealth]

Hi peeps back to the sump

So hopefully the 3rd attempt with the sump will be the final

This motor came with a front sump and the guys who did the conversion decided it would be a good idea to put in this turd of a rear sump that just constantly leaked lol. It was warped and the welds were poor

So I came up with the bright idea to get the later model aka 3uz sump. It is known as a rear sump but it’s actually not of a mid sump . I still had to modify it slightly as it was catching on the subframe. Nice thing about this sump is it is way lighter and has a splash plate

I never mentioned this before but after getting it modified it never sat straight. So I hammered it straight as I could. Another thing that I was never happy with is that after modifying it I had again reduced the volume of oil

Below is a pic of the back then new sump installed with the clearance

I am not gonna lie I don’t plan on taking it easy on this car haha. So I decided that I should get a proper sump as after watching a few Lexus v8 videos that I would eventually run into a oil starvation issue.

So I got my buddy to build the final sump

It’s and after market rear sump pretty much like the first one but it will be lighter. Can hold more volume of oil. Not leaking. Baffled with chambers with flaps. Use of oem dipstick. Turbo oil return. Magnetic drain plug and have a windage tray/splash plate.

This was the result. Not yet completed but you get the idea I hope

Next is to test fit it on the motor

Still need to update the thread with the work done from the teaser pic I posted last. Just lazy


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[Captain_Stealth]

FFS !!!

2021 has given me a nice start. Got issues with the sump lol

I suppose custom parts is trial and error lol but busy working through it


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[Captain_Stealth]

Sump issues sorted and pickup complete

It’s bolts up perfectly and Turbo drain was moved from the front to the side

Short piece of tray now secure to sump as there was a concern that it might move and damage internal parts

Decided on using the original pick up head.

Below pic is an idea how it will sit inside the trap doors

Final pic of oil pickup tube

So sump done

Oil pump modification nearly done just need 1 part will post final product tomorrow


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[individj]

well done man making progress

 

[Captain_Stealth]

well done man making progress

Hi buddy much appreciated,

more to come just been lazy lol

 

[Captain_Stealth]

I must say out of everything on this car this for me was my favorite item to do

I love the simplicity of these engines which probably is the reason that they are so popular and reliable.

Since I will be reusing my oil pump and now that I have a larger oil displacement I decided to inspect a used oil pump that I had and possible upgrade it

From what I could find could hardly find any wear on the gears which is incredible.

However the housing and backplate did show some wear which was to be expected but I don’t this will be an issue

There is a company called XAT who modified these OEM pump to perform much better. Since I have 2 of these oil pumps I decided to experiment

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[Captain_Stealth]

So the tools used for this type of work were

Impact driver - out of all my tools this is my favorite
Dremel and bits
Hammer
Circlip pliers
Brake cleaner
Motor oil

Here is the pistons from the pressure relief valve cleaned up quite nicely

Below are some of the areas that were worked on to remove the rough edges and change the ports shape slightly for better flow

After

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[Captain_Stealth]

Oil drain behind the crank seal enlarged

Before

Unfortunately I don’t have a pic

After

Didn’t go too big but hopefully it did the trick

After I was done and ready to assemble gate it a thorough clean with brake cleaner to get rid of all the metal shavings

The washer at the bottom was what it was before I ground it down. The purpose is when you shim the pump it should give you more pressure. Just need to be careful as you don’t want too much pressure. If I want to reduce the pressure I just need to take the sump off and remove the washer. So it’s worth the try as I am sure the old pump has lost some of its pressure anyway

Once I was done I lubed it up well using motor oil and assemble with some thread locker

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Luckily a lot of the yank V8 use a similar oil pump which helped me understand which parts to modify

Thanks for viewing the post I have been meaning to put up is of the cylinder heads. Still busy with them had to buy another dremel as the previous one burnt out after owning it for more than 10 years lol

Just need to get cracking on it.

 

[Captain_Stealth]

Getting there slowly

Intake done !!!

Gasket matched the top and bottom intake manifolds to the middle gasket.

Removed these casting marks.

Shaved off the sharp edge from the bottom of the port and beveled the edges

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[Captain_Stealth]

Same story just on the top manifold. But I didn’t gasket match this one. Just removed the sharp edges and and beveled the edges

Both cylinder heads are dismantled point some port. Polish and gasket match to a certain degree

Did a quick test on cleaning one of the cylinder chambers and ports with oven cleaner and some brushes

Worked really well need to give it a second try and compared to heavy duty degreaser this is a much easier option

Now that I got my new dremel hoping to get the head work done so I can send them to the engineers to get skimmed


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[Missioner]

Search for Jafromobile on YT. He has a phenomenal video on his channel about porting an polishing.

 

[Captain_Stealth]

Search for Jafromobile on YT. He has a phenomenal video on his channel about porting an polishing.

Ok cools will do have watch quite a few already. I plan on a basic job but a substantial improvement to stock. Not plan on spending hours on it

I have 32 valve ports. 8 intake ports and 8 exhaust ports




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[Missioner]

Ok cools will do have watch quite a few already. I plan on a basic job but a substantial improvement to stock. Not plan on spending hours on it

I have 32 valve ports. 8 intake ports and 8 exhaust ports




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You make a good point. 32 ports is a lot to do.

When I did my Golf motor 8 ports took the better part of a day. Like yourself I didn't go to so much trouble as to make them shiny, simply straighter and smoother. It did make a decent improvement.

 

[Captain_Stealth]

Forgot to add this

Basically this little plug is to remove the heater pipe that goes to the back of the engine.

Below is a pic of the pipe I want deleted

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[Captain_Stealth]

Lost a good friend today who I met in the car community and gave me good advice and often chatted for hours.

R. I. P. Mark Watson

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[Gordvisr]

condolences

 

[Captain_Stealth]

Hi peeps, in an unfortunate turn of events I will be needing to stop my build as an opportunity has come my way to purchase one of my dream cars.

Having 3 cars at the moment isnt helping with that so need to clean up house and unfortunately the beemer and my prelude need to go

I will be selling some of the parts that were not installed but plan on selling the car as is really sad but I think its for the best as I still have quite a bit to do here and to complete and then sell will not make sense at this point

Thank you for the following and support

 

[Missioner]

Sorry just reread your post from July.

Still keen to see how this car has ended up and if the new owner has continued your build to the same standard.

If he is a forum member perhaps he could post updates on this thread or post a link to the new thread if it exists.

Shot.

P.S. what did you buy as in dream car you mentioned?

 

[Captain_Stealth]

Sorry just reread your post from July.

Still keen to see how this car has ended up and if the new owner has continued your build to the same standard.

If he is a forum member perhaps he could post updates on this thread or post a link to the new thread if it exists.

Shot.

P.S. what did you buy as in dream car you mentioned?

Hi buddy sorry for the late response yeah been through a bit of a roller coaster in my personal life.

Porsche plans on hold for now as for the car I decided to part it out as I was getting offers of 20k and 30k

The car looks like this at the moment eish not how I wanted it to go but so far I have re-cooped 120k with a few parts over which are up for sale

currently shell is on sale lol

 

[Missioner]

Oh wow.

That escalated quickly.

The car was mostly complete and now it's down to a semi complete shell.

Sorry to hear about all the setbacks, personal and otherwise. Don't feel bad, I totally get it. I had to sell my daily due to having issues making payments. I know it's not exactly the same, but still shit.

Best of luck with the remainder of the vehicle, you might be able to unload to a used parts dealer if all its Natis is intact, an undamaged shell should get about R5kish bare.

Hopefully your fortunes change for the better and I can live vicariously through the new thread.

Merry and happy etc. May next year be better for us all.