E28 M5 S38 Engine Refresh

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HealeyBN7
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Re: E28 M5 S38 Engine Refresh

Post by HealeyBN7 »

malcolmr18zoy wrote:How are you altering the fueling system to compensate for the larger displacement?
Malcolm
Still gathering information... Looks like two options.

Option 1 - Install an adjustable fuel pressure regulator and bump the pressure from 3 bar to 3.5.

Option 2 - Install a Miller WAR chip and redo the fuel map. In theory I should be able to find a previously dynoed map for this combination and make adjustments to that baseline. In addition to the expense, tuning hassle and the fact that I'll have to add an additional bung in the exhaust to run my LM-2 wideband, I am hoping for Option 1.

Yes I know.

Dean
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Re: E28 M5 S38 Engine Refresh

Post by HealeyBN7 »

Pulled the engine off the stand yesterday. Installed a new clutch, starter and mated the transmission. Then got the idea that it would be helpful to fabricate an engine stand that holds the whole lump at the correct angle so I can slip it under the car and install it Porsche style.

You can see it is tilted at a serious angle.

Using the leftovers from the Peerless body buck, this welded mish-mash came into being. You are looking at version two. Version one was too much like a sleeping Reliant Robin. The big wheels should help as it had to make it's was down to the barn.

I have no idea if this will work, but it it does, I'll be happy happy happy...

Dean

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Re: E28 M5 S38 Engine Refresh

Post by Martin Keller »

Hi Dean,

Are you sure your not building some strange three wheel vehicle with one hell of a motor..... :D ......I just have not figured out where you will sit....... :devil: ......
Those headers are a work of art. Did you fab them up as I do not think I have seen a set like that before. VERY NICE. :thumbs:
:drive
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Re: E28 M5 S38 Engine Refresh

Post by DaveC »

Very inventive! Though if you're making a hot Reliant Robin, you'll likely need the engine in the other way around.....
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Re: E28 M5 S38 Engine Refresh

Post by spitfire »

Have you tried a leak down test with smoke? It might show the location of the leak more clearly.
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HealeyBN7
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Re: E28 M5 S38 Engine Refresh

Post by HealeyBN7 »

Considering it only took 33 seconds to pull the motor, I guess I could have started this swap a couple months ago.



I am committed now.

Dean
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Re: E28 M5 S38 Engine Refresh

Post by Steve Simmons »

Cell phone format violation!!! Surely it wasn't Austin who did that. :P

Sure looks easier to lift the car and leave the engine on the ground that doing it the other way around.
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Re: E28 M5 S38 Engine Refresh

Post by Larry Kluss »

Well done. It looks a little like a Keystone Cops short, but without the engine falling out or the car falling off the lift :D
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Re: E28 M5 S38 Engine Refresh

Post by HealeyBN7 »

Everything is hooked up with the exception of the exhaust...

First starting attempt.



Took it around the block after a few minutes of run in. Seems smooth and consistent. Trans, new clutch and shift bushings feel nice.

Got home and nothing dripped out. Just need to fill up the AC with R12.

I guess I have to give it 500 miles before stomping on the right pedal. oh the restrain.

Dean
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Re: E28 M5 S38 Engine Refresh

Post by malcolmr18zoy »

Hi Dean,
I'm just curious as to why you're using R12, and not R134a. Since you've had the system all apart, why not move to R134a refrigerant?
Malcolm
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Re: E28 M5 S38 Engine Refresh

Post by HealeyBN7 »

malcolmr18zoy wrote:Hi Dean,
I'm just curious as to why you're using R12, and not R134a. Since you've had the system all apart, why not move to R134a refrigerant?
Malcolm
Malcolm,

I had a few left over bottles of R12 and I didn't drain the compressor oil. I took the easiest path to a cold cabin!

Still need to sort out the AFR. I hope to hook up the LM-1 this weekend and see if it is too lean. I suspect that it is.

Dean
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Re: E28 M5 S38 Engine Refresh

Post by HealeyBN7 »

It has been a long time since I posted an update. Engine is running well and to sort out the air/fuel needs I installed an ECU chip that can accept custom fuel and ignition maps. This led to a dyno session where the tuner maximized the WOT (wide open throttle) maps and high demand part throttle areas.

The car runs great at WOT and with high PT loads. All areas that Dan, the tuner, focused on, but off idle and light loads were not adjusted from the base tune.

For our (California) smog test the car passed visual ;) , but with Dan's map I failed the 25 mph smog with high HC and very high NOX (three times the max).

The dyno tests are performed at 15mph (second gear) and 25mph (3rd gear). Both the gear and mph are state mandated. You can no longer select a lower gear for the tests. My smog guy says the Porsche guys ruined it for everyone, by fudging on gear selection. Now for the M5, neither test exceeds 2,000rpm.

Here are the maps that Dan provided after a day of dyno tuning (last year).

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Here are the part throttle fuel and ignition maps that I ended up creating last weekend to pass smog. It didn't take too long using an LM-2 and recording AFR values in 1,500 - 2,500 rpm ranges. It is hard to see, but we backed off the ignition a lot at the low load/low RPM ranges and reduce fueling as well.

This just barely got me by as my HC and NOX values are just below the threshold. It took three tries, making progress each time. The car runs much smoother off idle now. Driving in stop and go traffic/parking lots is also much easier as the ECU is no longer hunting (by swinging the fuel injectors (rich to lean) to find 14.7 in the low rpm ranges. I hadn't realized how much I compensated for this by pushing in the clutch early before stops and getting out of gear while just rolling along. It feels much more like Donna's 528e at parking lot/driveway speeds...which is a good thing.

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Learning how to adjust the fuel maps was fun, but passing smog was even better.

Dean
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