The unlikely donor

[Sankekur]

This past weekend I replaced/fitted the following:
-intake manifold with the better one that came on the early V8's
-fuel rail to match the slightly different intake manifold
-newer/fresher injectors
-early M62 throttle body
-new PCV plate
-new gaskets for everything
-some new vacuum lines and vacuum blank plugs

A couple of pics

Changed the intake from this:

to this:

Thanks for watching.

 

[RAArmstrong]

Awesome stuff :thumbs:

The car is a credit to you! raise:

 

[abharoochi]

Awesome work so far!!!!

:inlove: Loving this thread... Glued i am!:thumbs:

opcorn:

 

[Quick///M]

Thats a classic, nice!

 

[444YYY]

Looks great!!! :bravo:
Intake manifold from earlier V8's you say? BMW V8 or other V8?

 

[Prev]

Great work Sankekur :bravo:

 

[Redline]

Thanks for all the kind words guys.


So after the mountain road trip mentioned in the first post I decided it was time to do the clutch....not that I just felt like doing the clutch, I am crazy, but I am not "that" crazy....the clutch was starting to slip more and more.

The car ended up standing for two and a half months due to waiting for parts and me (and some other six speed owners) exploring every possible avenue of soursing a clutch by different means....in the end it was either going dealers or import things myself.....all of which were expensive options...very expensive options. So in the end it was clear to me that it would not be possible to do it cheaply....so if I am going to be paying allot I might as well pay a lot and get a upgrade at the same time.
This "upgrade" was one of the fruits of our (I say our because I was at least not alone im my searching) many searches I found that the clutch used on the 850CSi is in a lot of ways very similar to the what is on the 540i6....with two very distinct differences, it uses a single mass flywheel and the clutch is one of the biggest known to man, at an astonishing 280mm (there are actually a lot of clutches bigger, it just sounds more dramatic this way)
So on to some pics:
The new clutch and flywheel:

The old clutch and flywheel:

The clutch was actually not that badly worn but it was slipping due to oil contamination. The leaky rear main seal had made quite a mess of the back of the motor:

So cleaned off and a fresh rear main seal fitted:

New clutch fitted:

So because the car was standing so long I had a good chance for "while I am in there"-itis and "while it is open"-oids
So I also fitted a 3.15 LS diff:

Fitted a e60 545i SS with all new shifter bushes and rubbers:

And also replaced the gearbox with another one that I just "happen to have laying around":

And also fitted Powerflex anti-roll bar bushes front and rear:

Thanks for watching.

OOOOOOOOOOOOOOOOOOO,

I will start my savings plan now for if you ever want to sell.

Some very intelligent upgrades that will only add to the driver experaince.

 

[Sankekur]

Thanks for the kind words gents.

@444YYY, early BMW V8's (93-94 I believe)

 

[KAKA]

Wow Sankekur!!
I love it!!
When I was a kid my dad had a similar 540i
It brings back memories..
I only wish I had the passion and know how to take on a job like this!!
Congrats and thanks for the motivation!!
And the car... :inlove:

 

[applehero]

Nice project there Sank. Wish I had some space around for something similar.

How does the Single Mass flywheel compare to the Dual Mass unit? Thinking of the best route to go.

 

[Sankekur]

Wow Sankekur!!
I love it!!
When I was a kid my dad had a similar 540i
It brings back memories..
I only wish I had the passion and know how to take on a job like this!!
Congrats and thanks for the motivation!!
And the car... :inlove:

Thank you.

Nice project there Sank. Wish I had some space around for something similar.

How does the Single Mass flywheel compare to the Dual Mass unit? Thinking of the best route to go.

Thank you.
Well it should last longer than a DMF, it is cheaper that. The clutch engagement does somehow feel sharper. On the down side it does lead to a lot more gearbox noise, though this can be prevented for the most part.

 

[Gizmo]

Early M62 throttle larger than M60 unit?

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Nice work btw.:thumbs:

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She has come along way, damn!

 

[Sankekur]

Sort of, the inside diameter of both are the same, but the throttle plate on the M60 has extra plates added to make the throttle plate's leading and trailing edges thicker.....not sure about the reasoning behind this, though most seem to feel it is to make the throttle response less jerky at small openings.
M60 throttles B40 and B30

M62 throttle (has to be an early one, as the later ones where drive by wire)

Granted this is not a proven to actually give gains, but it might, and I was busy with the things in anyway so I thought what the hell.

 

[gconry18]

Amazing work you are doing here Sank. Love that cleaning job you did on the rear of the motor.

What degreaser did you use?

 

[Sankekur]

Thank you.

I normally use a solvent based cleaner to break up the worst of the oil...especially if it is old deposits, I follow this with a water based cleaner and this I just rinse off with water. Application is normally done with a small brush with stiff bristles, a used toothbrush works really well.
Then repeat if necessary.

Solvents I used is either Castrol, wynn's or spanjaard. (For really though spots I also recommend using carb cleaner, but this should be used with care as apparently it does attack some plastics)
In the case of the back of the engine I used Shield water based cleaner, but I have since started using prepsol, it is the best water based cleaner I have ever used, by a very long shot.

 

[Sankekur]

Gave the engine bay a clean. The engine bay is now almost in a state that I am happy with it.

Thanks for watching.

 

[gconry18]

Sexy!

 

[pre325]

Timeless classic...

 

[Gizmo]

Wow that engine bay has come a long way!

 

[Prev]

Inspiring raise::bravo: