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E46 M3 (2001-2006) Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006.


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Old Sun, Apr-16-2017, 03:59:18 AM   #71
ApolloTheGod
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Default Re: S65 Swap into E86 (Similar to E46)

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.
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2007 Black Sapphire Metallic + Imola Z4 ///M Coupe
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Old Fri, Apr-21-2017, 06:27:31 AM   #72
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Default Re: S65 Swap into E86 (Similar to E46)

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.
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Old Fri, Apr-21-2017, 06:47:55 AM   #73
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Default Re: S65 Swap into E86 (Similar to E46)

So clean. Love it!
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Old Fri, Apr-21-2017, 10:48:46 AM   #74
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Default Re: S65 Swap into E86 (Similar to E46)

Loving the red covers. Great work so far
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Old Fri, Apr-21-2017, 12:30:22 PM   #75
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Default Re: S65 Swap into E86 (Similar to E46)

Clean engine with red covers looks awesome



This picture is like nails on a chalk board, even though I know the block there is scrap!
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Old Fri, Apr-21-2017, 05:56:13 PM   #76
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Default Re: S65 Swap into E86 (Similar to E46)

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Originally Posted by Obioban View Post
Clean engine with red covers looks awesome



This picture is like nails on a chalk board, even though I know the block there is scrap!
I felt the same way when I realized that was going to be the only way to chain it up so that the chain was not in the way of the trans!
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2007 Black Sapphire Metallic + Imola Z4 ///M Coupe
S65B40A Swap, DCT, Apex ARC-8, GC Coilovers, H&R Sways, 996 BBK, Straight Pipes, Underdrive Pulley, Tune, aFe Intake


2011 Space Gray + Fox Red ///M3 Coupe
ESS VT2-650 SC, Bilstein PSS10 Coilovers, AP Racing BBK, Recaro Seats, Carbon Fiber Roof, GTS DCT Tune
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Old Fri, Apr-21-2017, 07:34:42 PM   #77
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Default Re: S65 Swap into E86 (Similar to E46)

Painful to see, but knowing it's serving a greater purpose

Better to end up as someone's coffee table than powering some clapped out E92 anyways!
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Old Fri, Apr-21-2017, 07:35:38 PM   #78
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Default Re: S65 Swap into E86 (Similar to E46)

The red valve covers look awesome.
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Old Fri, Apr-21-2017, 08:56:31 PM   #79
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Default Re: S65 Swap into E86 (Similar to E46)

Quote:
Originally Posted by twentyseven View Post
Painful to see, but knowing it's serving a greater purpose

Better to end up as someone's coffee table than powering some clapped out E92 anyways!
She will end up as a coffee table in my workshop. Greater purpose is to give rise to the stiffest chassis being mated with one of the greatest motorsport engines of all time.

Quote:
Originally Posted by kippers4brkfast View Post
The red valve covers look awesome.
I have an extra set I was thinking about doing and see if anyone wanted them.

I may have a big update later. Got huge boxes arriving today...
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S65B40A Swap, DCT, Apex ARC-8, GC Coilovers, H&R Sways, 996 BBK, Straight Pipes, Underdrive Pulley, Tune, aFe Intake


2011 Space Gray + Fox Red ///M3 Coupe
ESS VT2-650 SC, Bilstein PSS10 Coilovers, AP Racing BBK, Recaro Seats, Carbon Fiber Roof, GTS DCT Tune
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Old Mon, Apr-24-2017, 04:11:13 PM   #80
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Default Re: S65 Swap into E86 (Similar to E46)

how many hours do you have in this now? How many months has it been since the s54 came out and project began? thanks, looking really good man!!
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Discussing S65 Swap into E86 (Similar to E46) in the E46 M3 (2001-2006) Forum - Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006. at BMW M3 Forum.com (E30 M3 | E36 M3 | E46 M3 | E92 M3 | F80/X)