S65B40 Swap into E86 M

[Smartbear]

Brilliant, thanks for sharing. Calling TomK

Haha, yes I spotted this a few weeks ago on zpost. Fantastic project and something I've been pondering for a while. I'd want to keep the M3 6Mt so any advice you can give for me on that op would be much appreciated!
Best of luck with it.

Im sure the op mentioned he was getting a 6mt figured out just for those who might be interested?
Rob

[alekos911]

Lovely thread! Good luck with the build and keep us posted!!

[TomK]

Brilliant, thanks for sharing. Calling TomK

Haha, yes I spotted this a few weeks ago on zpost. Fantastic project and something I've been pondering for a while. I'd want to keep the M3 6Mt so any advice you can give for me on that op would be much appreciated!
Best of luck with it.

Im sure the op mentioned he was getting a 6mt figured out just for those who might be interested?
Rob

Indeed, hence me asking...

[Beedub]

yesssssss.

don't get tempted supercharge it...... it'll be undriveable.

[stevo///m3]

This chap has a fair set of cojones! Let's hope it all works out. Sounds like it'll be done by the end of May
Bit more adventurous than a two litre turbo...
Stevo

[Apollo]

Update time!

I dropped the exhaust to get more clearance and work out a better flowing system. As you can see in the first picture the S65 headers bolt up to the E46 exhaust system so all that is needed at a basic level is just rerouting and one can maintain the same flanges. Makes for an easier job.



Getrag DCT trans next to the S65




Time to pull this sucker out...




Let's compare...





It does appear the DCT is a tad longer. Shouldn't be a problem.

The next challenge to work out is figuring out how to do all my hosing and tubing for coolant, AC, powersteering etc. I've come up with what I believe is a really simple and great idea. Retain the stock fittings but weld on AN connectors to run custom hosing. The pictures should explain this further. I'll have these done before next week is out.



Material removed



All the connectors



I will have to remove the heater core to take by my welder to have the connectors fabbed up



Inventory time



Everything labeled



Getting the DCT trans into it's seating position



Getting a spare S65 block into position to see how it lines up with the trans and subframe and rack






Obviously nothing is perfect fitment here but we are only going for ballpark estimations right now. I still need to look at my headers before I build engine mounts





Everything is high enough to not cause any safety issues










Here is how the trans mostly fits. You can also see why I have to relocate the heat exchanger








I'm looking at getting the E9X condenser and deleting my drier bottle from the Z4. The E9X condenser has a built in drier so there is no need for the bottle which would free up some room in engine bay.

[Chris_D]

Awesome update.
This has to be the most compelling thread on the forum at the mo!

[Scooba_Steve]

Amazing work.

[kis]

Great build thread! The very best of luck with the rest of the project and I'll continue to follow with interest!

[enzed4]

Subbed. Awesome build so far

[Apollo]

Doing a swap with a manual car makes this a thousand times easier. I would encourage manual over DCT unless you want something truly unique. With a manual you can use your same original gauge cluster, clutch pedal and lines, and you don't need to run wires and things into the car and splice harnesses. The only wiring is in the engine computer box to get the MSS65 DME wired up.

Update.

Got the Z4MC driveshaft out and compared it with the DCT driveshaft.




Packages have been coming all week and will continue for a few weeks. I ordered the E9X AC condenser because it has a built in drier to save space in the engine bay so I can delete the E46 style drier bottle. I picked up a 19 row Mishimoto oil cooler for the DCT trans (It's way bigger than it looks) and I picked up the CSF Racing Engine Oil Cooler from the E92 M3 as it's the best size for the money it seemed and I wanted the inlet and outlet pipes on opposite sides otherwise the E46 M3 one was attractive. I decided I will retain the stock PS radiator as it does a swell job and is very large. Coolant radiator is in the mail. My wallet is starting to feel lighter after some of my orders this week. We have about $15k worth of items heading in the next couple weeks.



I like to take pride in the builds I do and a BIG part of that, probably the biggest part for me anyway, is having a clean swap. I cannot stand grime or dust left in anything! I had to tear down the exterior of the engine and get her cleaned up. My OCD is killing me!

I'm taking this time to do all the gaskets and get my AN fittings welded on the PS pump, AC unit, and OF housing.

First step was to seal up the engine.



I took the headers off to get in the outlet ports and clean some of the debris out.




Cleaning out the valley of this beast was tricky. It dawned on my to flip it upside down and hit it with a powerwasher after letting it soak in brake cleaner.











Up next was dropping on some of the first goodies I did up earlier on.















I called it quits for this day and got her tucked in for bed



Next day I got her prepped for my new rod bearings I ordered. After the S54 I am not taking any more chances.




More to come soon.

[Machine monkey]

This is a really nice project.
Having done a Lexus v8 swap into a Toyota supra fairly recently. I know and agree on the benefits of having an aluminium v8 in place of cast steel straight six. We did virtually the same swap you’re doing but with Toyota bits. So i know how much $$$$ and time this will take up. All the very best to you buddy and keep the updates coming

[Yorkie Z]

I can't believe this has only two pages of comments so far.

I love your attention to detail. In a perfect world you'd be my next door neighbour and Keira Knightley on the other side

Keep up the awesome work

[Darkangelv2]

Not a lot to add. Love watching the progress and will look forward to each update as they come!

[Artful-Bodger]

There's some serious thought going into this,