mlytle

mlytle's M2 madness

1,045 posts in this topic

NOTE 11/19/13 - this is a very long thread with a LOT of build information.  if you are looking for a specific part of the build, use the forum search.  just type what you are looking for in the search box, make sure the blue box to right of entry box says "this thread" and hit the search button.  results will only include findings in this thread.  hope you find information which is useful in this thread.  that is my goal in documenting all the changes i make.

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As I am starting to accumulate enough parts and time to start this project, i might as well start a project thread on it!

It all started with this: a 75 that needed some love.
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then i found this that happened to have a better engine: a 73 with B&B'd engine with eric kerman head work, schrick cam and sidedrafts
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the good engine was moved to the 75, a bunch of other upgrades were done and I ended up with this:
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the 73 shell was sold to Noah (of N2 project fame) who put it back together with his spare parts.


I should have stopped right there! but then this showed up: 74 with S14.
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it also came with this 76 "kit" car with tons of brand new parts that i have no idea what i am going to do with:
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this will be the subject of either another project thread or a for sale ad at some future time....

ok, at this point i have realized i have a problem. i have purchased 4 02's in a year. three of them were purchased just to get the engines that were in two of them! help?

so now after 700 miles of use, i begin the process of taking a perfectly good and strong 2.0l cammed and sidedrafted engine out of my redone 75 and putting a dusty S14 in its place. this will not be a quick project. I will be drivng the 75 through this fall while i take the S14 out of the purple shell, clean/refresh it and plan the swap. anyone think there will be scope creep here? i am trying to be good, so please do not mention carbon fiber airboxes or alpha-n fuel management. or schrick cams. :-)

the wife is off on vacation for a week, so a perfect time to start mucking with this. the 75 was moved to her spot in the garage and the purple car entered the shop. hmmmm, what to do first? how about washing it? maybe compounding out the trunk lid? i know, this is like wasting a nice steak as the last supper for someone going to the electric chair, but oh well....

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before:
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after:
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more as the story develops....

Edited by mlytle

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So where did this purple M2 come from? I am trying to piece together it's history. apparently this car was converted as one of the first projects to use the Aardvarc M2 conversion kit back in the late 90's. the engine VIN traces to a JAN88 build US spec M3. the person who owned the M2 at the time was Craig Harries from Worchester, Mi. at some point the car was sold to someone in central Virgina, where it sat for a long time. Then Jay in Baltimore bought it, and it sat untouched for several more years before i acquired it. as far as i can tell, it has been unused for 5-10 years. unfortunately the drivers side frame rail is swiss cheese. the car got new stock brakes, new hard and soft brake lines, billy sports, eibach springs, new ebrake cables, turbo exhaust system, new stub axles and rear hubs, a 5spd, a 3.91 LSD and a fiberglass air dam as part of the original conversion.

If anyone has any info about this car or the current whereabouts of Craig Harries, I would love more detail!

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LOL....I assumed you would be an enabler Ray! I have already poured through Nick's site copying all the engine bay pics....and am avidly reading s14.net and s14power.com. there are many bad influences at work!

The purple M2 on Nicks site is the one I have, in happier days.

John's CF airbox is looking good...if for no other reason than it fits over the tii booster I already have in the 75.

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The purple M2 was not in safe driving condition since it had been sitting for so long. lots of issues. but I had to know if the driveline worked before I put it in the 75. can't drive or work on an ugly car, so I made it pretty by compounding and waxing the whole thing (pics on pbucket http://s397.photobucket.com/albums/pp59/mblytle/purple%20kit/). It ain’t perfect, but it does not look like a POS from 50ft away anymore! Then I got the basic lighting working for safety..brake, parking, headlights, turn signals, rehabbed entire throttle system, bled out clutch and front brakes (rear brake cyl’s are frozen), and did nut and bolt check on all steering, suspension and driveline parts. Last minute I added a bunch of techron fuel system cleaner to the tank to run it through.

Took the 75 around the neighborhood as a warm up doing memory imprint of the power…..came back and gingerly took the m2 out. As expected, only having front brakes with rusty rotors and non-functional brake booster made stopping interesting, but…after dragging the brakes for a half a block enough stopping power was restored.

HOLY COW! That car hauls butt! Yee ha! Get in second gear and drop the hammer and you are GONE! Any hesitation I had about going through with this swap has been erased. :-) the difference between my sidedraft engine and the S14 was remarkable. I had to force myself to get back in my yard and stop terrorizing the neighborhood with a silly grin on my face. oh yeah, I was supposed to be doing a systems check…. Water temp was rock solid mid gauge when moving. (It had been ¾ up just sitting idling as I have been doing for last few months.) Clutch is very grabby..suspect rust on flywheel and sticky t/o bearing. Tranny seems to shift fine going up and down in gears. Engine pulls smoothly right up the rev range. Do not think I will tear into it to refresh anything, just new water pump and check rod bearings while swapping the oil pan. New radiator and t-stat is a must. And complete cleaning of engine and painting of valve cover of course.

The car stopped and turned like crap due to the brake issues, the dead stock suspension and disconnected sway bars. Pretty scary having just got out of the 75….but it was functional enough for the test.

I am going to miss the growl of the sidedrafts for sure as the S14 sounds like a sewing machine, but the s14 power and the suspension/brakes of the 75 are going to be fun!

I may start taking it apart tomorrow. I wonder if I can get the driveline out before wife gets back on Monday……

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Marshall,

We would never encourage you to make unnecessary modifications to your 2002. Nope, not us, never....

Ian

M2_airbox_02.jpg

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This is actually all your fault Ian...seeing your car in Miami a, ahh, long time ago planted the seed....;-)

is that the cf airbox that fits over the tii booster on your car? did you go with john's maxx alpha-n/CF combo?

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So the plan is to put the s14 engine in the red car? I hope you'll spare no details as you dissect Barney...

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This is actually all your fault Ian...seeing your car in Miami a, ahh, long time ago planted the seed....;-)

is that the cf airbox that fits over the tii booster on your car? did you go with john's maxx alpha-n/CF combo?

You'd need to check with John which booster his airbox for the M2 clears. I have John's DTM M3 airbox, since I converted to Tilton pedals and no longer have a booster to get in the way. I'm converting to Megasquirt instead of the Maxx alpha-N, although many people like the Maxx system a great deal.

Ian

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Pretty sure I have a rotated tii booster, with John's airbox.

Don't worry Marshall, the cf airbox makes lovely noises! There's a few vids on S14power.

I have a dyno run vid here tho it may be difficult to ascertain where all the noises originate!

http://smg.photobucket.com/albums/v355/raykoke/?action=view&current=MVI_0026.mp4

Cheers,

Ray

This is actually all your fault Ian...seeing your car in Miami a, ahh, long time ago planted the seed....;-)

is that the cf airbox that fits over the tii booster on your car? did you go with john's maxx alpha-n/CF combo?

You'd need to check with John which booster his airbox for the M2 clears. I have John's DTM M3 airbox, since I converted to Tilton pedals and no longer have a booster to get in the way. I'm converting to Megasquirt instead of the Maxx alpha-N, although many people like the Maxx system a great deal.

Ian

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lovely noises indeed! :-)

the gb on s14power for john's airboxes did say the 2002 version only fits the tii booster. may be an early xmas or promotion present! like i need an excuse to buy more car "stuff"....

now that the engine is out of hibernation and has been run a bit, i'll do one more round of compression and leakdown tests and then get it out of the car. last round was right after initial start up. 215psi +/-8psi and leakdown 5-10%. leakdown was not coming from the intake or exhaust valves. think the head has been off the car and redone.

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Sounds like the motor is fairly healthy!

I guess you read that John is offering a closed-loop alpha n now, in case you want to go that route.

What diff is in the purple car? (Oh it's a 3.91 I see now). I recommend 4.10 gears with the 5sp OD. Heheheh!

Cheers,

Ray

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yes, did read that. and i happen to already have an innovate LC-1. just need to add second o2 location in exh manifold.

if I had not just had Aardvark make me a 50% lock 3.91 for my 75, i would have done a 4.10. the 3.91 in the purple car will be a "spare". :-)

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Got diverted yesterday oogling and exercising an 02 friend’s other cars…including an original Audi Quattro Sport with significant mods good for 350hp at the wheels and a Porsche Ruf Turbo also with significant mods for 340hp or so at the wheels. Yikes! Several other killer cars too. OBMWC..he has 70 Alpina 02, 83 E21 320 (M20) race car and soon to be restored M635.

So today I got back in the M2 game with one more round of engine tests.

Compression: 230/230/230/225

Leakdown: 4/9/3/13 % loss (all loss appears to be in the rings. Can hear hissing in dipstick tube, but none in intake or exhaust.)

Here is link to video of engine bay and exhaust with car revving and of the compression test of #3&4 cyls:

Any thoughts on sights and sounds? Several of the blips were to 6500rpm. Blew some blue and brown smoke. Wonder if that is just from sitting for so long? Engine only has about 1.5hrs of running time (mostly just idling) after not being used for many years. the gas does have a bunch of gas preservative and techron in it.

Here are two pics of spark plugs. They are in the order they came out with #1 on the left in first pic and on right in second. Looks like there was water in the plug wells at some point.

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Here is pic from underneath the exhaust manifold. Notice the #4 flange is different color than the rest and looks like something was leaking under it.

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See anything worth being concerned over?

Time to return to shop to drop exhaust, driveshaft and drain all the fluids!

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Make some progress taking things apart…

Exhaust system off

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Exhaust manifold removed(note…a lot easier when center track rod removed!)

Does everyone use the stock m3 manifold? Looks like it must be dented to clear the idler arm.

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The Y-pipe looks cheesy. Pinch bends. May have to have new one made. I assume this has to be a custom part for an M2.

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Driveshaft out (looks good, u-joints in great shape)

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AFM off

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Some wires labeled

Engine block oil drained (getting the oil cooler and lines drained will be interesting..) Oil was very clean.

Then I noticed the installer jacked up the engine ¼ in for some reason. Both sides. Would explain why it was hitting the hood.

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Trunk getting full!

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Update:

More taking apart this weekend. Cooling system removed

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Intake plenum removed. Hard to see, but the intake on head looks perfectly clean

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Fuel lines and injectors removed, tank drained.

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this set of injectors and another set i have will be sent to RC Engineering for cleaning and balancing. the best of the 8 will go in the car.

Engine electrical harness labeled and removed

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Setrab oil cooler and lines removed

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One less M2 in the world….for now.

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With the help of Jim G, S14 and trans were removed from the purple 76, returning it to “normal” 2002 status. No major issues with the removal. Trans slid off without issue before we pulled the S14 out the top.

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Looks like trans, a 5spd from E21, has leaking seals at the shifter input shaft and speedo cable input port. Input and output shaft seals are dry. t/o bearing needs replacement. Slave cyl looks new. Need to clean trans up a bit.

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S14 came out carefully. Tight fit! Going to need to be more careful dropping it back into the 75, we “dinged” the wonderful paint on the purple car in a few places..

First challenge was getting the engine on the stand. I wanted to mount it from the exhaust side, but the S14 block is missing the upper threaded boss the M10 has that I used before. Ended up mounting by flywheel end after removing the clutch.

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Clutch does not look too bad, but will be replaced. This must be an M3 clutch as it does not look like any 2002 clutch I have seen.

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throttle bodies removed.

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Do these intake ports look worked over? Valves look a bit dirty.

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Exhaust valves look well carboned too.

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Next valve cover came off. Looked pretty clean in there. I assume these are stock cams?

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Timing chain and upper guides look good.

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Is this a stock timing chain tensioner?

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Looked a little wet by rear main seal, but thie inside bell housing was dry.

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M2 no more

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And the pile of parts on the shop floor is growing!

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Cleaning Day!

working on dirty greasy cars drives me nuts, therefore all must be cleaned. Lined up all the M2 parts and broke out the power washer.

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Engine cleaned up well

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As did the trans and various misc engine pieces

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And I finally found the perfect deck decorations….2002 turbo exhaust system, S14 manifold and a driveshaft.

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There will be a slight pause in the project…have 4 days at the track for a race this weekend, have to change gears to race car prep.

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slight pause caused by maint on this...

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and then "introduced" the two targets of this project...the S14 and the 75

:-)

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Man that race car looks mean, full cage and everything! Awesome! One of these days I'm gonna get out there to meet you and see all these awesome machines. Good luck this weekend out at Summit Point, and have fun!

Chris

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Man that race car looks mean, full cage and everything! Awesome! One of these days I'm gonna get out there to meet you and see all these awesome machines. Good luck this weekend out at Summit Point, and have fun!

Chris

mean enough for tons of checkered flags and multiple mid-atlantic SCCA championships! :-) it is built to limit of SCCA ITR class rules. it is "just" a 325, but i routinely beat M3's in BMW club races.

i did notice a different feel bringing it back in the shop after months of 2002 work. wrenching on 02' is kinda "fun" and the cars just seem "happy". the e36 race car on the other hand, just says "serious business'. purpose built, no BS. git'er done!

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You should find the answer (and more) to the chain tensioner question here.

http://www.e30m3project.com/e30m3performance/installs/installs-3/tensioner/index.htm

Tommy

thanks for the link! some good info there!

odd, my tensioner looks like neither the stock one or the e36 one. looks like a stock one, but there is what looks like a bleed valve on the end of it.

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