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Date: 3-17-07 06:34
From: m20ohtwo in Mountain View, Calif.  
Subject: Re: M20 six-banger saga  
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I've been making progress but unfortuantely I cannot take the appropriate pictures because my camera has broken.
The intake manifold, radiator/fan and throttle cable/linkage has been installed. Next up is the fuel pump. I've decided to go with the twin pump system from an early e30 325 because of the availablility of spares from the junkyard. The pre-pump was installed (very easy- just r&r with a good rubber o-ring). But now I'm debating whether to mount the main pump in the trunk or under the car. I'm leaning towards the trunk- in the spare tire well. My fuel filter is a nice bosch one that was only $12.00. I was replacing my girlfriend's in her 88 325is and decided to get a second one since it seemed so perfect.
Doing the throttle cable wasn't too bad - I followed the directions in "six into two does go" and happened across an old honda cvcc in the junkyard and grabbed the throttle cable. The part I had to dream up myself was the connection of the cable to the throttle lever at the pedal box. I came up with a nice simple solution I wish I had a photo of - it involved welding a nut on the bottom of the lever end and bolting on a small plate with a second hole for the cable end. _________________ -Daniel
M20 swap blog: http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,277525/
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Date: 3-22-07 08:02
From: m20ohtwo in Mountain View, Calif.
Subject: Re: M20 six-banger saga
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It wasn't the CIVIC cable it was a CVCC cable. Big difference there. See the M20 FAQ for a link to "six into two does go" for more info.
I wish my camera worked because I'd also like to show off my fuel pump/filter setup, which is nicely hidden under the trunk boards with my spare tire intact. I used a smaller filter from a fuel injected ford and the early e30 twin pump setup.
Hopefully I can take pics this weekend. _________________ -Daniel
M20 swap blog: http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,277525/
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Date: 3-25-07 09:28
From: m20ohtwo in Mountain View, Calif.
Subject: Re: M20 six-banger saga
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Here's my low cost fuel pump set-up. It uses the in tank pre pump and external pump (pictured rear of gas tank) from an e30 325. I went this route because spares are easy to come by from the junkyard. The fuel filter is used on several fuel injected fords and was only $15.00. I used it so I could fit everything under the trunk boards (the e30 filter doesn't fit).
Note: the stock plastic fuel line will not be used in its entirety to pump return fuel through the interior of the car. Its under suction as the main line in a stock vehicle so it only draws air if it develops a leak. Pressurizing it is a non-no. I will be using the metal return line, however, since it runs under the car. _________________ -Daniel
M20 swap blog: http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,277525/
Last edited by m20ohtwo on 4-9-07 12:50; edited 1 time in total
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Date: 4-8-07 11:59
From: m20ohtwo in Mountain View, Calif.
Subject: Re: M20 six-banger saga
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Finally got some pictures taken:
Early 90's VW golf a/c radiator mounted with 12 inch fan on front. Overflow tank for the same golf, only $20 new with cap from autohausaz.com.
simple bracket holds peg on rad.
Using this accordion piece seems a necessity to bolt this thing together and lne up the flanges.
Edis wheel mounted. Came off a Thunderbird V6. It mounts on a modified power steering pulley.
This thing should be ready to fire up in a few days. The MS is built and wired up. Just waiting on an ignition coil and wires to come in the mail. I also have to register the darn thing again. It's been off the road two years now! _________________ -Daniel
M20 swap blog: http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,277525/
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Date: 4-20-07 08:11
From: m20ohtwo in Mountain View, Calif.
Subject: Re: M20 six-banger saga
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So I finally got the car running last weekend, but it wasn't the happiest of days. The engine seems to have horrible vibrations and rattles above 2500 rpm, and I have a hunch my efforts to save $300 on proper balancing of the pistons, rods and crank has resulted in this horrible situation. I seriously wanted to die when I realized this mistake.
That said, I really enjoyed taking it around the block, rattles and all, after over a year of sitting. There really is nothing like a 2002, and it really cruises effortlessly with the m20 in there. _________________ -Daniel
M20 swap blog: http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,277525/
Last edited by m20ohtwo on 4-20-07 10:23; edited 1 time in total
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Date: 4-20-07 09:26
From: snowflake in Quebec
Subject: Re: M20 six-banger saga
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That really sucks man, nothings more aggravating than trying to do a perfect job and it turns out bad, i hope it's not as bad as you think it is, any chance the vibrations above 2500 rpm might be caused by polyurethane engine mounts/ tranny mounts if your running them.
I'm not sure what engine management your running, but this is just an idea.
If you are running the megasquirt, maby somthing is out of wack with timing/spark, wont notice to much at idle but then when rpm increases things get crazy, maby just hook up the motronic, if it's not already hooked up.
For the brief moment that you did drive it, It's good to hear how effortless it was driving around,
Failure is not an option
Keep pushing forward.
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Date: 4-20-07 10:27
From: m20ohtwo in Mountain View, Calif.
Subject: Re: M20 six-banger saga
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Thanks for the encouragement. On my list of things to do is back off the ignition advance. I've heard that too much will cause the crank to vibrate badly on the m20. At first I thought my valves were hitting the pistons- the noise was that bad. _________________ -Daniel
M20 swap blog: http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,277525/
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Date: 4-21-07 04:36
From: snowflake in Quebec
Subject: Re: M20 six-banger saga
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Yah, i'd do that and if that doesn't work give the mtotronic a try,
If you took a stock crank and bolted up the stock connecting rod with new pistons i don't see any reason why the engine would rattle,
I know there not balanced from the factory, there's a little variation of weight(grams's) between them, so i'm thinking that's not your problem and that it lies with the engine management, timing/spark, somthing is out of wack, it may even be detonating itself(preignition) kind of like if your where turboed and pushing alot of psi. you need to retard the timing because so much air is pressed into the chamber, that the spark takes place when the piston is still rising to meet Top Dead Center, which results in pinging.
Maby this is why you where hearing, all those rattles. I hope you didn't do to much damage driving around the block, cause once you sort out the timing/spark, the car's going to fly.
Timing and spark are dificult for me to understand, that's why i'll run the motronic at first, your already leaps ahead of me running megasquirt.
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Date: 6-8-07 09:48
From: m20ohtwo in Mountain View, Calif.
Subject: Re: M20 six-banger saga
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I finally got the engine apart this evening. The block is still in the car, I was able to get the connecting rods out without removing it. I was relieved that I was able to work around the suspension crossmember. The oil pan came out fine after I reached in the gap and removed the oil pump.
This is going faster than I thought. If I didn't have to wait for parts I'd have it done this weekend.
I'll be measuring the rod bearing clearances thoroughly this time, they seemed a lot looser than I remember during assembly... _________________ -Daniel
M20 swap blog: http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,277525/
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Date: 6-9-07 10:26
From: m20ohtwo in Mountain View, Calif.
Subject: Re: M20 six-banger saga
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It turns out that the rod bearing clearances were much too large and are the obvious cause of all that racket. I used standard size bearing shells when I re-assembled the engine with the new SETA rods and pistons. It turns out that the crank had been turned way under size, by about .025 of an inch. I can't believe the thing even ran the way it did with such massive bearing clearances.
The good news is this thing will be done in a few days. I just need to get some new bearings.
This is the first engine I slapped together like this. Before I was the super anal type that would spend months just putting the short block together, checking everything with a micrometer. I guess everyone needs to make stupid mistakes at some point. _________________ -Daniel
M20 swap blog: http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,277525/
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Date: 8-20-07 04:05
From: m20ohtwo in Mountain View, Calif.
Subject: Re: M20 six-banger saga
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I've finally started driving my m20 2002 after several snafu's delayed completion for several months. I forgot how much I love my 2002.
There is so much more torque- I was actually quite surprised. The only thing I can compare it to is my 383cid chevy nova, but of course this car is much more civilized and sweet. As I drive and look out over the hood I feel the long six out in front of me and it all just feels right. I can't wait to take it out on the track. I'm also content to sit and listen to it idle in the driveway- its got nice lump to it thanks to the 323 cam and the straight through magnaflow muffler.
I was thinking I'd have to turbo it, but I don't think that will be necessary.
The only thing I wish I did was lighten the crankshaft and flywheel more- the lack of engine braking with an m20 is creepy. Having all those cylinders means more power per cubic inch of displacement - but also more rotating weight.
The MS still needs some tuning, particularly in the accelleration enrichment area. I also have a leaking gas tank now because the car was sitting for so long! _________________ -Daniel
M20 swap blog: http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,277525/
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Date: 11-8-07 12:34
From: -=Charley in SoCal
Subject: Re: M20 six-banger saga
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if i had to do it again, i'd definately go with the pre-pump/res setup. with no baffling the in-tank pump is subject to starve in tight corners (which is why i cant let my tank go down further than 3/4 anymore). with the reservoir, i dont think that'd be a problem. _________________ King of Avatar
M20-02 blog
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Date: 11-8-07 12:40
From: m20ohtwo in Mountain View, Calif.
Subject: Re: M20 six-banger saga
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Yeah the two pump deal is the way to go. Replacement pumps can be had much easier/cheaper. My uncle just gave me 4 good used main pumps for free (he used to replace them when they were still good as part of routine maintenance for the wealthier customers). _________________ -Daniel
M20 swap blog: http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,277525/
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Date: 12-29-07 12:14
From: m20ohtwo in Mountain View, Calif.
Subject: Re: M20 six-banger saga
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The car has been mechanically sound for a while but I've had setbacks in tuning it. I recently put in some tested ford 19lb injectors, hoping to fix the rough idle it has (I thought the stockers might have been leaking). The exhaust still smells incredibly rich, like unburned fuel. It has a surprising amount of power, but the exhaust smell is strong enough to make me nauseous.
I've also got my wide band LC-1 controller finally working, which says it has a 14.7:1 mixture at idle. I'm baffled.
I am going to try some different settings in Megasquirt today to see what happens. _________________ -Daniel
M20 swap blog: http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,277525/
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