"160i" 6.0l Motor Swap Build - @ls1series

[highbrowed]

This thread is to document the swap of a GM LS 6.0l V8 (L96) into my 2009 135i.

Before (5/14/21):
My N54 with a DocRace 6266 kit. I spun a rod bearing even though I never beat on the car and religiously changed the oil with Motul every 3k miles:



Current Status:
Swap is complete in NA form and it's quite a riot. All features of the car function as they should (Gauges, ABS, AC) with the exception of TCS and cruise control:












Parts list:

• GM L96 6.0l V8
• Holley Terminator X Max ECU
• OEM GM LS3 intake manifold
• OEM GM LS3 throttle body
• OEM GM LS3 camshaft
• OEM GM LS3 injectors
• OEM GM LS3 coil packs
• OEM GM LS3 accessories
• Melling high pressure oil pump
• Mishimoto oil catch can
• ICT Billet aluminum manual belt tensioner
• PowerMaster low profile starter
• PMM low clearance oil pan
• PMM oil pan baffle
• PMC LS > GS6 transmission adapter
• PMC single mass flywheel
• PMC sintered 6-puck clutch disk
• Turner Motorsports stainless clutch line
• OEM BMW E39 M5 clutch pressure plate
• OEM BMW 135i DCT driveshaft
• LSE90.com engine mounts
• LSE90.com accessory drive
• LSE90.com coolant overflow tank
• LSE90.com CANbus intrgration
• LSE90.com 1 7/8" runner long tube headers
• Custom 3" true dual exhaust with X-pipe and Vibrant resonators
• Precision Raceworks Walbro 450 in-tank bucketed fuel pump
• RedHorse Performance Teflon coated stainless braided PTFE fuel line
• StopTech drilled and slotted brake rotors
• EBC Red Stuff brake pads
• BimmerWorld stainless brake lines
• Earls stainless power steering high pressure line and fittings
• Custom 4" cold air intake system with K&N filter
• Custom trunk battery tray delete with H5 battery relocation
• Custom engine bay aluminum heat shielding
• DEI fiberglass heat protection hose sleeves
• Custom AC pressure lines
• Sanden AC compressor
• Custom Alcantara interior
• OEM BMW Motorsports golf ball shift knob
• OEM BMW Individual alcantara steering wheel
• OEM BMW Performance shifter and brake boots
• OEM BMW Performance carbon license plate frame
• OEM BMW Performance carbon fiber trunk spoiler
• OEM BMW black line tail lights
• OEM BMW 1M rear bumper diffuser
• BimmerWorld 1M style rear bumper
• OEM BMW/BBS Style 187 wheels
• Burger Motorsports front and rear wheel spacers

[highbrowed]

Update: 5/15/21 - n54 is almost ready to come out.





Update: 5/21/21 - New motor is on the way. Donor vehicle is a 2016 Chevrolet Silverado 2500HD.





Update: 5/22/21 - N54 delete mod complete

[TM9030]

[houtan]

Sweeeet!! Subd

[Petro135]

Great timing. Im looking at another 135i. I want to use the engine to build for my car and drop an LS in the new one. Ive been researching this. Will be following!!

[ferocity02]

What's going in? LS2?

[highbrowed]

Originally Posted by ferocity02

What's going in? LS2?

L96, Gen 4 low compression iron block truck motor with LS3 heads.

[ferocity02]

Originally Posted by highbrowed

LY6, Gen 4 low compression iron block truck motor with LS3 heads.

Any reason not to use an aluminum block? That will save you around 75lb in the front end, better weight distribution too. LS2's aren't hard to find. They can handle the boost with proper supporting mods.

[Clayn5x]

jeez excited to see this thing run for the first time! How much power do you want to make?

[r0nd3L]

Fun project!

What's the status of the N54 that's coming out? Blew it up?

[ShocknAwe]

Nice. Fabricating all mounts or using one of the LS swap kits

[highbrowed]

Originally Posted by ShocknAwe

Nice. Fabricating all mounts or using one of the LS swap kits

Using mounts from LSE90.com and PMC adapter to adapt the BMW ZF 6-speed to the LS.

[ShocknAwe]

Originally Posted by highbrowed

Using mounts from LSE90.com and PMC adapter to adapt the BMW ZF 6-speed to the LS.

What's your solution for the dme communication and accessories like radio aircon etc?

[highbrowed]

Originally Posted by ShocknAwe

What's your solution for the dme communication and accessories like radio aircon etc?

They all work without the DME. I'm using a Holley Terminator X Max to control the engine in place of the DME.

[ferocity02]

Would a 6L80E fit? The ZF six speed will be your weak point if you want to add more power. There's plenty of proven upgrade options for the GM transmissions, not so much for the ZF.

[highbrowed]

Originally Posted by ferocity02

Would a 6L80E fit? The ZF six speed will be your weak point if you want to add more power. There's plenty of proven upgrade options for the GM transmissions, not so much for the ZF.

It'll fit but I want a 6-speed manual. The BMW ZF has the same torque rating as a T56, so it's apples to apples, and it's more cost effective to use the BMW transmission with an adapter. A good used T56 can be quite expensive.

I'll just roll with the ZF until it breaks.

[ferocity02]

Oh gotcha, I was thinking the ZF 6HP21, not the manual. Good choice!! Less electronics to mess with too.

[r0nd3L]

Originally Posted by highbrowed

Not sure on the exact number., but I've always wanted a 9-second street car since Fast and Furious lmao




I spun a rod bearing probably due to a leaky injector. I was religious about oil changes every 3k miles and never ran with low oil.

I'll crack open the pan this weekend and confirm for sure. I think the N54 is coming out today.

Ugh, sucks!

[drwillb]

What about traction control or Stability control? How will those systems integrate into engine control?

[highbrowed]

Originally Posted by drwillb

What about traction control or Stability control? How will those systems integrate into engine control?

Not worrying about either. TCS and DSC will get deleted.

[drwillb]

Originally Posted by highbrowed

Not worrying about either. TCS and DSC will get deleted.

Hardcore. Cool.

[mistacarder]

This will be a lot of fun!