M54 engine swap - how difficult/long to do

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mrscalex
Joined: Fri 13 Mar, 2015 09:14
Posts: 910

  Z3 roadster 1.9

M54 engine swap - how difficult/long to do

Post by mrscalex »

With the 2.2 Cat C'd project hopefully passing the MOT Monday and taking to the road I'm thinking about the next project for the autumn. Will be enjoying the 2.2 over the rest of the summer first :)

My knowledge of engines needs to catch-up the rest of my knowledge so I fancy taking on an otherwise nice car with a stuffed engine. It will need to be cheap though :)

I've done engine swaps before, Ford Crossflows and Pintos on Escorts many years ago. It was easy enough taking it steady and following the manual.

So is it likely to be much more complicated on a Z3? I tend to do 2-3 hours work a week on my cars. So may be 6-8 sessions, ie weeks?

Any special tools required other than an engine crane?
ImageImage
2001 Z3 2.2 Topaz Blue (Trudy) - Keeper rebuilt from a write-off
2002 Z3 2.2 Titan Silver (Cookies) - Keeper rebuilt having been bought with a seized engine
2002 Z3 3.0 Sapphire Black (Peanut) - Keeper awaiting rebuilding having been bought as an abandoned project
Plus Willy, Kodak & Maycee - All 2.2 Sport projects. Yes, 6 is a lot of Z3s :)
Always happy to try and help with spares :)
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Brian H
Joined: Tue 16 Dec, 2008 19:55
Posts: 2505

  Z3 roadster 3.0i

Re: M54 engine swap - how difficult/long to do

Post by Brian H »

If you are swapping like for like, no problem, just be methodical in you approach, if you are converting this is a different kettle of fish, still perfectly feasible just needs researching thoroughly before you start.
mrscalex
Joined: Fri 13 Mar, 2015 09:14
Posts: 910

  Z3 roadster 1.9

Re: M54 engine swap - how difficult/long to do

Post by mrscalex »

I once re-shelled a written off 2 litre Mk 2 Escort (itself built from written off RS2000 bits) into an 1100 Popular (happened to be the best shell I could find and a lovely one at that).

It was more a case of re-shelling rather than upgrading an 1100 but the whole experience taught me if you want an uprated car then just sell your current one and buy another one built to go faster from the factory. So I am strictly an as it left the factory merchant now.

So it will be a straight swap. I guessed okay on the current project at 2 months (doing about 6-10 hours a week). So I'm guessing 2 months for this one but cutting right down to 2-3 hours per week and I won't be starting until Sep or Oct. I'm sure I could do it in a weekend if I tried (not sure about a day as some people say) but I want to spread it out as no rush at all.

Unbelievably I only decided what type of project I wanted next this morning, I found one today and It's being delivered tomorrow! It will be loosing a few bits that will simplify getting the current project through the MOT tomorrow (principally its seats). Then I can kick the problem of finding a pair of Sports seats down the line until the new project is ready for them later this year.

Not sure what I will do with the new one when it's done, probably just sell it on as it's more about the challenge...

I feel another project thread coming on...
ImageImage
2001 Z3 2.2 Topaz Blue (Trudy) - Keeper rebuilt from a write-off
2002 Z3 2.2 Titan Silver (Cookies) - Keeper rebuilt having been bought with a seized engine
2002 Z3 3.0 Sapphire Black (Peanut) - Keeper awaiting rebuilding having been bought as an abandoned project
Plus Willy, Kodak & Maycee - All 2.2 Sport projects. Yes, 6 is a lot of Z3s :)
Always happy to try and help with spares :)
NZ00Z3
Joined: Thu 23 Jun, 2016 01:26
Posts: 95

  Z3 roadster 3.0i

Re: M54 engine swap - how difficult/long to do

Post by NZ00Z3 »

There is lots to consider. I've spent a lot of time looking at doing it. Still haven't got off the starting blocks as I'm looking for a 2.2 L manual (M54B22 engine) or a 2.8 manual (M52TU28 engine) ready for a M54B30 transplant.

Because the Z3 engines are computer controlled, it becomes a bit more difficult than swapping in a bigger engine, checking the size of the exhaust, fiddle with the carby and starting it up. You need to make sure you have the correct engine management ECU (DME) for the engine and transmission (auto/manual) mix you are installing. If you change the ECU you will need to get it aligned to the EWS (security module) or it will not fire up. Stay with the same ECU family if you change the ECU, that way you are not faced with a major engine management re-wire.

If you don't change the ECU, you will need to get the fuel management maps re-coded with customer numbers for the larger engine other wise it will run like a dog when cold.

It can be done, just need to do all the research before you buy the car otherwise you may have the wrong base for your intended upgrade.
mrscalex
Joined: Fri 13 Mar, 2015 09:14
Posts: 910

  Z3 roadster 1.9

Re: M54 engine swap - how difficult/long to do

Post by mrscalex »

Useful thoughts if you're upgrading the engine. But mine is a straight swap.

It would do my 'ead in working out all that lot. And I'll just go out and by a 3.0 car when I want one of them.

Good luck if that's your sort of challenge though :)
ImageImage
2001 Z3 2.2 Topaz Blue (Trudy) - Keeper rebuilt from a write-off
2002 Z3 2.2 Titan Silver (Cookies) - Keeper rebuilt having been bought with a seized engine
2002 Z3 3.0 Sapphire Black (Peanut) - Keeper awaiting rebuilding having been bought as an abandoned project
Plus Willy, Kodak & Maycee - All 2.2 Sport projects. Yes, 6 is a lot of Z3s :)
Always happy to try and help with spares :)
mrscalex
Joined: Fri 13 Mar, 2015 09:14
Posts: 910

  Z3 roadster 1.9

Re: M54 engine swap - how difficult/long to do

Post by mrscalex »

Will any M54B22 engine be a direct replacement in a Z3, eg from a 320i, 320Ci, 520i or Z4?

I'm hoping to get one with all ancillaries still bolted on to simplify things. If it came from another type of BMW would any of the ancillaries need swapping? Presumably the inlet manifold at least?
ImageImage
2001 Z3 2.2 Topaz Blue (Trudy) - Keeper rebuilt from a write-off
2002 Z3 2.2 Titan Silver (Cookies) - Keeper rebuilt having been bought with a seized engine
2002 Z3 3.0 Sapphire Black (Peanut) - Keeper awaiting rebuilding having been bought as an abandoned project
Plus Willy, Kodak & Maycee - All 2.2 Sport projects. Yes, 6 is a lot of Z3s :)
Always happy to try and help with spares :)
NZ00Z3
Joined: Thu 23 Jun, 2016 01:26
Posts: 95

  Z3 roadster 3.0i

Re: M54 engine swap - how difficult/long to do

Post by NZ00Z3 »

The core engine will be the same.

Various models have different set ups for controls powered by vacuum, so it would be easier to just swap your inlet manifold and vacuum services.

You will need to change the oil sump and oil pump suction line. The sump on the Z3 is a unique shape due to the closeness of the front cross member.
mrscalex
Joined: Fri 13 Mar, 2015 09:14
Posts: 910

  Z3 roadster 1.9

Re: M54 engine swap - how difficult/long to do

Post by mrscalex »

Okay, some definitive advice needed here please as I might be buying this engine:

http://www.ebay.co.uk/itm/BMW-3-Series- ... 568381618?

It's out of a 2004 E46 320ci. Despite the description saying it's a 2.0 I think it must be a 2.2 (as per title and I'm confirming anyway).

So I know from a previous post this will 'work' but I may need to swap some parts. Can anyone give me a definitive list of what I need to transfer from the old engine. I'm trying to gauge both re-usability from the old engine (it seized and hole in sump) and the additional effort.

And will I end up with a 'proper' Z3 installation? I don't want to be modifying/swapping ECUs, acheiving extra BHP etc. I want to end up with exactly the same build/spec that it left the factory with. Thanks.
ImageImage
2001 Z3 2.2 Topaz Blue (Trudy) - Keeper rebuilt from a write-off
2002 Z3 2.2 Titan Silver (Cookies) - Keeper rebuilt having been bought with a seized engine
2002 Z3 3.0 Sapphire Black (Peanut) - Keeper awaiting rebuilding having been bought as an abandoned project
Plus Willy, Kodak & Maycee - All 2.2 Sport projects. Yes, 6 is a lot of Z3s :)
Always happy to try and help with spares :)
NZ00Z3
Joined: Thu 23 Jun, 2016 01:26
Posts: 95

  Z3 roadster 3.0i

Re: M54 engine swap - how difficult/long to do

Post by NZ00Z3 »

You may need to swap sumps and oil pick up depending on the model of the donor vehicle. The Z3 has a low engine mounting and a special oil sump to keep the engine/sub-frame clearance.

Always take lots of photos of the hose spaghetti around and under the inlet manifold and label everything as you disconnect them. Check that the donor engine has all of the same connections and that there are no unused and open vacuum connections. Better to do this check with both engines on the ground so you can see everything. Sometimes if things are different, it is easier to just change the exhaust and inlet manifolds so you know that everything will marry up and you'll not have any problems

Vacuum and Crank case ventilation hoses will be old and have a high probability of breaking. check, check check.

Other than that, a M54B22 to M54B22 swap should be straight forward.

Special tools? You'll need a set of Torx sockets if you are separating the transmission from the engine.
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