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Why I am Swapping Motors


               
2012 Apr 9, 8:29am   7,412 views  16 comments

by bmwman91   follow (5)  

I sort of spammed-up a thread in the RE section with details of my latest car project, so I figured I would off-load some of that in here. I mean, it is probably more entertaining than the same-old whining & hoping for lower prices in the RBA, but it wasn't my thread.

So, I am in the market for a replacement motor for my vehicle. It is a 1991 318iS that I have been dumping money into since I got it in 2005 for $2000. I had an identical car prior to that (bought in 2000 as my first car) that I wrecked like the 21 year old moron that I was. Messing with that car got me into mechanical engineering, which I got a BSME in in 2007, and it has led me pretty deep into EE & software engineering through side projects with the control system & stuff. It is needless to say that I have a love of the car, and on top of being a source of hobbies & personal development, it is fun as hell to drive.

You just can't find a 2500lb sedan with room for 5 people & a load of climbing gear anymore, that also pulls 30MPG on the highway. Most new economy cars are faster, more fuel efficient and can probably take a corner faster with a good driver, but none of them are real driver's cars. I have rented & driven a ton of these cars, and they all feel like wearing socks in a bathtub. One of my main gripes is this electronic throttle nonsense since it robs you of a great deal of tactile feedback from the motor, and electronic stability control systems that easily override you. The other complaint is over-assisted steering. I used to run the car without power steering at autocross events to enhance the feedback!

OK, anyway, I was driving back from a climbing trip in Joshua Tree last week when part of the timing chain tensioning system let loose. Being that I have driven one of these cars for 12 years, I have built sort of a 6th sense for when things go wrong. Somewhere about 30 miles south of Kettleman City / CA41 I noticed what seemed like a new road noise. I knew it wasn't road noise, but what else was I going to do besides keep driving? I pulled off at CA41 to get gas & maybe a burger, and as I cruised to the gas station, I heard the sound of pistons & valves contacting each other that is so characteristic of this motor when the timing is off. SHIT! This particular motor was badly neglected by its previous owner, and I have had 2 major failures in the timing case in the last few years. I am big on preventive maintenance, but sometimes the remedy is a full rebuild, which I have been putting-off.

Here is what broke this time. Yeah, the stupid sprocket was fine, but the casting it mounts to broke off! Sheesh!

Thread w/ pics: http://www.m42club.coms/showthread.php?t=14748

Honestly, I really haven't been able to trust the motor in the last few years, and was considering other cars at one point. Last year, a little tensioner sprocket's bearings blew out and I spent 40 hours over a 3 day weekend tearing the motor apart & cleaning the hell out of everything in hopes of refreshing it (without pulling the head or dealing with main bearings).
What's wrong with this picture? This was last year's problem.

Thread w/ pics: http://www.m42club.coms/showthread.php?t=13574

I replaced that sprocket ($160 part, OUCH!) & put the motor back together. Well, a couple of months later I was getting some nasty noises from the front of the motor. I suspected a stripped bolt. Yup!

Thread w/ pics: http://www.m42club.coms/showthread.php?t=13720

The bolt head was working its way through the timing case cover lol. After fixing that, the really awful noise was gone. However, I still got this yucky rasping/knocking noise when the motor was fully warmed up & running 3100-3400RPM. I had the case open again to check everything, but nothing was loose or broken. It was a mystery! Well, after [whatever] failed last week, the nasty noise at that RPM was gone, replaced with the sound of a poorly constrained timing chain.
I have had other trouble with the motor, although further in the past. In 2006 the oil pump ate a chunk of timing chain roller. The previous owner hadn't maintained the motor very well, and even though I rebuilt the timing chain assembly, I was an idiot & didn't drop the oil pan to look for pieces! These are generally pretty reliable motors that you can get 300,000 miles from...but that requires pretty active participation in proper maintenance. I guess 220,000 miles isn't too shabby, considering the PO's neglect & how hard I drove it.

Page w/ pics: http://bmw.e30tuner.com/my318is_pic_oilfailure.php

So, I am tired of putting time & money into this 22 year old motor with 220,000 miles. I am NOT tired of the car itself though, and I can't imagine myself in a new car, or some (economical, reliable) boring inexpensive used econobox. I wish I was the type of person that didn't care about what I drove beyond "does it go when I put the key in," but I am not. Well, I have been wanting a fully built version of this motor for 6 years. 205HP, 9000RPM redline, bulletproof construction with all of the weak points redesigned & modified. Now's the time for it haha! Once I get hitched later this year...nope, not going to be able to justify the cost of this built motor. Still, it is cheaper than a new car, and these motors are more reliable than the originals. I expect to pull at least 150,000 miles from it, and that includes race events on top of daily driving.

Who are my fellow grease monkeys in here? Got any fun projects going, or just good home repair adventures?

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1   bmwman91   @   2012 Apr 9, 8:42am  

Oh and for reference, here is where I am SUPER glad that the car didn't break down on me!

Highway 247 to Barstow:
http://maps.google.com/?ll=34.724467,-116.990333&spn=0.034743,0.052314&t=h&z=15&layer=c&cbll=34.724467,-116.990333&panoid=q1UNQe_dzUSvMkBz3LHo1w&cbp=12,337.78,,0,4.5

Highway 58 to Bakersfield:
http://maps.google.com/?ll=35.011684,-117.906604&spn=0.017381,0.026157&t=h&z=16&layer=c&cbll=35.011684,-117.906604&panoid=Rua_t7qOI06LByWa4-iUhg&cbp=12,100.11,,0,-0.59

Kettleman City is about 164 miles form my parents' house (and they are cool with me dropping my car there when it needs work since my father has every imaginable tool). I live about 20 miles form them, so I can get over there for projects pretty easily.

Anyway, I could have had AAA tow it at no charge, but I was really irritated with the motor & decided to drive it as far as it would get me. Well, as it turns out, revving the motor over ~2500RPM got the oil pressure high enough that the hydraulic tensioning piston for the chain pushed hard enough to keep everything in good alignment! So, 162 of the 164 miles were actually trouble-free since I was on the highway at constant RPM. The car still pulled 29MPG and the motor had full power. It was just the last two miles of stop lights where the car was really unhappy.

The car actually gave a death cry as I was driving home. I consider it a sign that I should toss the motor rather than fix it (again). The f***ing horn button started sticking about 5 miles from home on highway 85. So here I am, clunking down the highway and randomly honking like a goober. Sheesh. At least the horn button is an easy 5 minute fix.

2   Honest Abe   @   2012 Apr 9, 11:05am  

I was trying to up load a picture of one of my hot-rods but goofed up....I don't know why.

3   bmwman91   @   2012 Apr 9, 11:23am  

It's cool. That rosemary picture makes me want to pan-fry some pork chops!

4   elliemae   @   2012 Apr 9, 1:03pm  

bmwman91:
I love it when you talk dirty!

5   bmwman91   @   2012 Apr 9, 2:26pm  

You should have SEEN the gunky shit that built up on this motor when I cleaned it off last year. There was 1/4" of road dirt & old oil built up on most of the front-facing surfaces of the motor. I had to get a metal pan, a gallon of paint thinner & a toothbrush out to rectify that, since the motor was mostly disassembled. The ultrasonic cleaning tank also helped. I love showing up for my office job with cut up hands & perma-grease that doesn't go away because it is IN the outer layer of skin. The only other guys at work that I know of that work on their cars at all are our lab techs. The engineering staff...I don't think that they change their own oil.

Funny side-story:
The skid plate under the motor was really nasty with leaked oil & power steering fluid, and all sorts of dirt. Basically, due to its design, I needed some sort of very large pipe cleaner to get the crap out of the worst spots on this thing. I went to a local hardware store & asked the guy if they had large pipe cleaners of some sort...like 3" in diameter and at least 24" long, for my car project. He sort of looked at me for a minute, and told me that they had just what I was looking for. He also informed me that I was the first person to ask for one of these that DIDN'T ask him where they could find "bong cleaners." I got a good chuckle from that.

The skid plate.

Why does the car have one? Well, yet ANOTHER misadventure led me to it!

Yeah, that's all of my motor oil on the ground. I hit a rock on my way out to my favorite cliff jumping spot on the Stanislaus Rivver in 2006. Oops. 12 miles from cell service...bummer. Still, it was a fun fun day on the river since I didn't notice this until we were done & back at the car.


Story & pics: http://bmw.e30tuner.com/my318is_pic_panbreak.php

6   zzyzzx   @   2012 Apr 10, 1:58am  

I don't understand how you could be going through timing chains so often.

7   bmwman91   @   2012 Apr 10, 3:26am  

The timing chain is fine, I have never heard of one breaking in my 12 years in the E30/318iS community. It is the rest of the assembly that seems to have issues. A couple of people have had the bearings on that little sprocket blow out, and I guess that seems reasonable after 200,000 miles. The busted timing case casting is another thing though, and it is bullshit. I know of one or two others that have had that happen, and in the last year too. Maybe the cast ribs are a bad design & cause a stress concentration or something. Being aluminum, there's no endurance limit, so it is bound to fail at some point. Anyway, it is feasible that the casting was damaged when the sprocket failed last year. Even a small nick in the rib could be all it took.

But, since this motor seems to be of dubious reliability (previous owner didn't maintain it well, I drove it really hard), I am putting in a completely refreshed one with a modified timing assembly. The guys that are building my new motor change it to a single-row chain, which greatly reduces the inertial loading on the components. The single row chain has been track-proven to be just as reliable as the overkill double-row one. They also knock off like 4kg of reciprocating mass from the valvetrain & crank assembly, and around 15lbs from the flywheel assembly.

The REAL question though, is can I even use the motor I want in CA? I am not TOO concerned about SMOG since the car's emissions are about 3% of the allowed limits in stock form. The fuel injection & ignition are fully electronic, so the built motor can still be tuned to pull 30MPG on the highway & run clean when the throttle is not fully open. However, 11.5:1 compression might not play nice with the 91 octane pump gas we are stuck with here.

8   elliemae   @   2012 Apr 10, 12:35pm  

RE: skid plate. Years ago I was driving I-70 in Colorado/Utah and there was a dead deer in the road. I could feel the skid plate connect with the carcass but it was winter & possibly black ice weather, so I couldn't avoid. We drove all night - when we got home the next morning the dogs were eating the "treats" off the skid plate. They're really handy for that.

9   Bap33   @   2012 Apr 10, 12:46pm  

10:1 is the max on pump gas, and the computer will keep retarding the ignition if you get any pre-ig going on, and that kills performance and mileage. Plus, 11.5 to 1 requires a very stout crank, main saddles, main caps, and head gaskets. Plus, crank case pressures will be puking oil out of every breather if you dont get great ring seating.

double row chain vs single makes ZERO difference in parasitic drag. The valve springs are the biggest drag, and the cam bearing drag is next. If you remove the valve springs the cam spins pretty darn easy. Just saying, but do as you wish. I'd look at some performance info and try to back up that chain idea.

In those motors it makes a little more sense to keep the compression down and use a blower or turbo to make it run. Easier to pass smog, easier to tune. A bone stocker with an air pump aide will see instant gains.

Just my uneducated opinion.

10   zzyzzx   @   2012 Apr 11, 2:25am  

I recommend Jasper engines. I have had once in my car for more than 10 years now. Expensive, but worth it.

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