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echo
04-04-2009, 03:30 AM
e30m42cab (Scott) knows me from way back on another forum and suggested I post my recently completed SC build thread here, so here it is - enjoy:

Build diary for my motor swap from m20b25 to m20b25 + Toyota SC14 supercharger pushing about 0.4bar on chipped motronic ecu.

Day 1, Beer 1:

Boat is finally out of the shed. Spent all of yesterday tiding it up and prepping for today. So here she is ready for dismantling:

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%201/SCInstallDay101.jpg

One bolt down, time for a beer...
http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%201/SCInstallDay102.jpg

Day 1, Beer 2:

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%201/SCInstallDay104.jpg

So a few more bolts... Exterior panels removed.

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%201/SCInstallDay103.jpg

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%201/SCInstallDay105.jpg

Day 1, Beer 3:

Cooling system and a few other bits out.

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%201/SCInstallDay106.jpg

Day 1, Beer 4:

Exhaust and driveshaft disconnected.

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%201/SCInstallDay107.jpg

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%201/SCInstallDay108.jpg

Day 1, Beer 6, 7 & 8:

Loom out, computer swapped over, powersteering drained, ancillaries removed, everything ready for motor removal tomorrow except for air con.

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%201/SCInstallDay109.jpg

So that's it for today.

Current beer count: 8

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%201/SCInstallDay110.jpg

Tomorrow morning a friend is removing the refrigerant from the aircon (so as not to make more holes in the ozone) and then tomorrow night I'll pull the old donk out.

echo
04-04-2009, 03:32 AM
Day 2, Beer 1

Air con out except compressor

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%202/SCInstallDay201.jpg

Weight saving: 8.5kgs = about the same as all the IC piping plus IC, so about an even swap then for SC setup

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%202/SCInstallDay202.jpg

Day 2, Beer 2

"Engine Hoist" arrives

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%202/SCInstallDay204.jpg

Day 2, Beer 3

Slowly does it...
http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%202/SCInstallDay205.jpg

Go Northland Rangi Tractor Styles!!!!!!!
http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%202/SCInstallDay206.jpg

Day 2, Beer 4 & 5

After a few hiccups (mainly to do with correct placement of winch chain and gearbox not wanting to clear subframe/sway bar).

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%202/SCInstallDay207.jpg

Day 2, Beer 6

Motor out. Obligatory dragon....

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%202/SCInstallDay208.jpg

Total Beer Count: 14

echo
04-04-2009, 03:33 AM
Day 3, Beers 1 & 2

Removed gearbox and clutch, test fitted IC, drank 2 beers.

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%203/SCInstallDay301.jpg

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%203/SCInstallDay304.jpg

Current Beer Tally: 16

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%203/SCInstallDay305.jpg

echo
04-04-2009, 03:40 AM
Day 4, Beers 1 - 3

Got lots of parts etc organised, cleaned engine bay, gearbox etc, drank 3 beers...

mmmm shiny!

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%204/SCInstallDay401.jpg

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%204/SCInstallDay402.jpg

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%204/SCInstallDay403.jpg

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%204/SCInstallDay404.jpg

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%204/SCInstallDay405.jpg

Current Beer Tally: 19

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%204/SCInstallDay406.jpg

echo
04-04-2009, 03:42 AM
Day 5 & 6

I had some time up my sleeve whilst waiting for parts and a couple of other things, so I decided to modify my factory SA sump guard. It is now SA sump guard LW fuh raze v1.0:

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%204/SC%20Swap%20Days%205%20and%206/SCInstallDay5609.jpg

And as some of you may know I shaved several litres and 7odd kg off my sub box install by making it 300mm shorter so it didn't take up the entire width of the boot. Obviously this meant a fair bit of redesign and reporting, but the final result is as follows:

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%204/SC%20Swap%20Days%205%20and%206/SCInstallDay5610.jpg

Then my parts etc arrived, so I could get down to business.

So new motor now out of the van, flywheel and clutch installed, gearbox fluids replaced, rear gearbox seal and selector shaft seal replaced, diff fluid changed, box ready to go onto motor:

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%204/SC%20Swap%20Days%205%20and%206/SCInstallDay5603.jpg

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%204/SC%20Swap%20Days%205%20and%206/SCInstallDay5604.jpg

Plus a few pics of the exciting bits for those interested:

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%204/SC%20Swap%20Days%205%20and%206/SCInstallDay5608.jpg

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%204/SC%20Swap%20Days%205%20and%206/SCInstallDay5607.jpg

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%204/SC%20Swap%20Days%205%20and%206/SCInstallDay5606.jpg

So motor will go into the car tomorrow night or Saturday (I'm going to a funeral tomorrow so depends on how much we drink at the wake whether I'm in a fit state to use heavy machinery).

Once it's in the real work starts cutting holes for the IC piping and making it all work.

Stay tuned!

Oh, and I know you're all dying to know....

Current beer count: 33

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%204/SC%20Swap%20Days%205%20and%206/SCInstallDay5614.jpg

echo
04-04-2009, 04:00 AM
Day 7

BMW Special Tool BMW3025 - home made thin-walled 30mm socket for removing flanged nut on gearbox output flange. Thanks to Glenn for showing me his so I could copy. Its a cheaper impact driver that I shaved down.

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%207/SCInstallDay701.jpg

I managed to fit the oil cooler filter housing from my old motor - had to bend one of the pipes a wee bit to clear the SC, but they perfectly miss the SC piping! Great Success!

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%207/SCInstallDay704.jpg

And finally - in! Lots to do, but its in its final resting place = win!

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%207/SCInstallDay703.jpg

http://i558.photobucket.com/albums/ss23/echothreezero/SC%20Swap%20Day%207/SCInstallDay702.jpg

Will do more tomorrow.

Beer Count = 39

echo
04-04-2009, 04:01 AM
Day 8

Busy day mocking up and test fitting everything. Of course everytime I moved something somethign else wouldn't fit.

I finally got the IC lines sorted, but then couldn't fit the oil cooler anywhere without it being a hazard for hitting the ground (bad since it contains the life-blood of the engine). So I got the sump guard to fit (a bit of hammer modification to get it to fit past the SC), and then flipped the oil cooler upside down and reversed the flow direction (swapped lines around) so hot end was still up, and voila!

Anyway, here are pics of the finished mockup - will bolt in place tomorrow and start rewiring and fitting everything else. Still lots of little finishing off to do aswell - rust protecting areas of bare metal, etc.

http://lh4.ggpht.com/_XETEo1BTLxg/ScSZo-dgUfI/AAAAAAAAADE/E169p-mScQs/s640/SCInstall.Day8.08.jpg

http://lh5.ggpht.com/_XETEo1BTLxg/ScSZ2dtbFyI/AAAAAAAAADU/d7tisZcB6QA/s640/SCInstall.Day8.11.jpg

http://lh6.ggpht.com/_XETEo1BTLxg/ScSZv4VOt2I/AAAAAAAAADM/xre6SPwdFp8/s640/SCInstall.Day8.10.jpg

http://lh5.ggpht.com/_XETEo1BTLxg/ScSZiJBIsOI/AAAAAAAAAC8/deF7C_9InE8/s640/SCInstall.Day8.07.jpg

Somehow I missed pics of the hot side of the IC piping and AFM. Will post tomorrow.

Beer Count= 48

echo
04-04-2009, 04:03 AM
Day 9

Not all that exciting today - lots of hours, not much worth taking pictures of. Basically I bolted up everything I mocked up yesterday, fabbed a few things, put most of the wiring back where it should be etc.

View of lower IC mounts and oil cooler. Note the trick oil cooler brackets - they are the original ones, cut down slightly and reversed so what used to attach to the car now attaches to the cooler and vice versa, then flipped upside down, and the rubber cooler mounts flipped. Looks factory.

http://lh5.ggpht.com/_XETEo1BTLxg/ScXlUBObuhI/AAAAAAAAAEI/yzdYV4ENhb0/s640/SCInstall.Day9.01.jpg

http://lh5.ggpht.com/_XETEo1BTLxg/ScXlbXUCeRI/AAAAAAAAAEQ/1MQcTzw8c1M/s640/SCInstall.Day9.02.jpg


I had to bend the oil cooler pipes slightly to make it miss the radiator - also had to trim a small bit off the bottom of the radiator tank (just part of the bracket) to gain the few mm I needed. At first I thought It was impossible until I realised I'd left the rubber radiator mounts out and that gained me 10mm.
The radiator tank is just out of focus at top left. Not the clearance with the tank trimmed - not much!

http://lh6.ggpht.com/_XETEo1BTLxg/ScXlhtO2ZoI/AAAAAAAAAEY/n4QpO3iEaIg/s640/SCInstall.Day9.03.jpg

http://lh4.ggpht.com/_XETEo1BTLxg/ScXlpFwOUMI/AAAAAAAAAEg/U1rpjNEH0A4/s640/SCInstall.Day9.05.jpg

Pics of hot side of IC piping and air filter as promised. may be welding a small piece of metal in front to replace some of what I removed. Initially I needed it all out, but rearranged things and managed to get it so I could have left a 15-20mm wide bit of metal there, so may weld it back - not sure of what the certifier will want.

http://lh6.ggpht.com/_XETEo1BTLxg/ScXlwUmX7LI/AAAAAAAAAEs/w7aH6YDh2Sk/s640/SCInstall.Day9.07.jpg

http://lh5.ggpht.com/_XETEo1BTLxg/ScXl2m_JxBI/AAAAAAAAAE0/LcG0qY7rjik/s640/SCInstall.Day9.08.jpg

BOV

http://lh5.ggpht.com/_XETEo1BTLxg/ScXmKTB6DJI/AAAAAAAAAFM/sg-wPRmFavs/s640/SCInstall.Day9.11.jpg

Beer Count: 52

echo
04-04-2009, 04:04 AM
Hooked the SC clutch feed up to pin 1 on connector c200 instead - power from ignition with ignition in ON position, but not when in START or ACC positions. I'm not sure whether the SC needs to to turn whilst cranking/starting, but started it 2-3 times so far OK. First time cranked for a bit to get fuel, and thyird time cranked a few times as I think it wanted a tiny bit of throttle to start. If it's always hard to start I'll try changing it to being on when ignition is in ON and START.

Was going to be a PITA to hook up to AC switch as the blower fan would always be on low, and there's a diode on the AC clutch feed, etc. i could have figured it out, but this is better I think.

So last night I bolted up d-shaft, heat shield and exhaust, and did some tidying of the wiring under the dash so the interior is all back together, fitted my new shifter boot (thanks Nathan B.), and gave it another run with exhaust fitted so I could fill and bleed power steering. Need to give it a shakedown run to blow some cobwebs.

Beer Count: 67

echo
04-04-2009, 04:06 AM
Drove it for the first time at 1am this morning (was supposed to finish at 10pm, but ran into a few hiccups, and I had decided I was driving it last night no matter what lol!)

I was very tired and it was dark, and first run so didn't push it hard (didn't want this post to be a " so I got the car going and promptly put it in a ditch") Went fairly well. Can hear the SC until the exhaust noise takes over, and the BOV is nicely muted. You can hear it in the car, but doubt you'd hear much from outside.

Pulls like f**k in 1st and 2nd, but on the roads I was on and the speed I was happy doing it was hard to say how much better 3rd and 4th were. I do know on the straight before my driveway I made an easy 10-15km/h more at a mailbox I use as a yard stick.


Some wrinkles to iron out, and a few things to do and It'll be done. So a few more beers yet, but not too many.

Beer Count: 74

Driveshaft loop is done.

Interior is dry and back together, seats have been cleaned and leather conditioned.

Think I fixed a prob with the alarm.

Exhaust wrapped the rest of the intake piping as being metal it absorbed heat rather easily and I had lots of wrap left.

Mounted a oil-catch-can of sorts. Looking to buy a shiny one.

Removed 4.5kg of sound deadening that was unecessary.

Beer Count: 86

echo
04-04-2009, 04:06 AM
Finished! Vids to come.

87 Beers

http://lh4.ggpht.com/_XETEo1BTLxg/Sdb-bRLIXhI/AAAAAAAAAHQ/Q6Lta68HswI/s640/SCInstall.FinalBeerCount.FinalBeerCountDSC03686.jp g

echo
04-04-2009, 04:09 AM
http://photos-h.ak.fbcdn.net/photos-ak-snc1/v352/26/8/1031533655/n1031533655_30170623_3358.jpg

http://photos-a.ak.fbcdn.net/photos-ak-snc1/v352/26/8/1031533655/n1031533655_30170624_3625.jpg

http://photos-b.ak.fbcdn.net/photos-ak-snc1/v352/26/8/1031533655/n1031533655_30170625_3916.jpg

http://photos-d.ak.fbcdn.net/photos-ak-snc1/v1902/26/8/1031533655/n1031533655_30223419_9751.jpg

http://photos-g.ak.fbcdn.net/photos-ak-snc1/v1902/26/8/1031533655/n1031533655_30223422_8455.jpg

http://photos-a.ak.fbcdn.net/photos-ak-snc1/v1902/26/8/1031533655/n1031533655_30223424_9001.jpg

SamE30e
04-04-2009, 04:00 PM
Nice!!

craz azn
04-04-2009, 10:38 PM
Haha, good read. Congrats on the build... patiently awaiting the videos...

E30M42cab
04-04-2009, 11:56 PM
seriously Graham, we're gunna need that video soon!

everlast
04-05-2009, 02:07 AM
Awesome! Vids will be sweet!

El Gato Liso
04-07-2009, 05:30 PM
http://img6.imageshack.us/img6/945/sploogek.gif