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

[highbrowed]

Originally Posted by ryanwrobel

Did you have to replace the dash? Did you have to use the wiring harness from the LS?

No, everything from the firewall back is OEM BMW.

The Holley Terminator ECU came with its own harness, I threw the BMW engine harness in the trash. The Holley communicates over CANBus so everything works out of the box except for ABS and Tach. I used a CanBox adapter to enable wheel speed and restore ABS and make the tach work again.

[highbrowed]

This weekend I decided to start tackling the AC system, as AC is a necessity in South Florida. Whoever designed this car made it quite difficult to access the evaporator; nearly everything under the dash had to come out, including the crash bar.





Closeup of the bad evaporator core:


Cleaned out the heater box and replaced all of the seals while I was in there:


I'd estimate the evaporator replacement took me about 8 hours to complete from start to finish. It's not difficult as long as you make sure to document how everything goes back together and keep parts organized as they are removed.



I installed new air vents as the original vents were very sun faded.















I had to update the Holley with some custom logic to read when the AC button is pushed over CANBUS and send a signal to the AC compressor clutch to kick on the compressor.

Now, for the first time in a long time, I have super cold AC again..


I also wrapped the headliner in alcantara fabric and swapped all of the grey interior trim pieces to new black pieces:










And nstalled 1M front suspension arms:






And installed 1M/M3 rear subframe bushings and black PowerFlex poly differential bushings.






And installed Bilstein B16 PSS10 coilovers and Dinan camber plates:












And installed BimmerWorld stainless brake lines:

[picklz]

Looks awesome man, this is very similar to the path I'm considering going down.

Question for you on the driveline, reading throug the posts it sounded like you swapped your driveshaft for one out of a DCT 135i, is that correct? Did you order that online or source one locally? Any other changes or parts you needed (outside of the PMC adapter)? Also what clutch did you end up going with?

Appreciate you posting, nice to see successful swaps.

[highbrowed]

Originally Posted by picklz

Looks awesome man, this is very similar to the path I'm considering going down.

Question for you on the driveline, reading throug the posts it sounded like you swapped your driveshaft for one out of a DCT 135i, is that correct? Did you order that online or source one locally? Any other changes or parts you needed (outside of the PMC adapter)? Also what clutch did you end up going with?

Appreciate you posting, nice to see successful swaps.

Hi, yes the driveshaft is from an n55 135i DCT which I sourced locally. The DCT driveshaft is about an inch shorter than the 6MT driveshaft and still mates to the 135i rear end via the unique differential nut.

I used the clutch included with the PMC kit which I believe is a 335is clutch, but I'll be going with something a bit more heavy duty soon as I'll be boosting the car.

[highbrowed]

I was having an issue with the stock mounts not giving me enough clearance between the engine and steering rack, so I installed some PMC Motorsports polyurethane motor mounts:






While I was in there I also installed Condorspeedshop transmission bushings:

[WrathOTM]

Oooo, those mounts are sooo girthy!

Sorry couldn't resist.

[houtan]

Nice work!!

That Tee fitting that you used to splice the expansion tank drain to the heater line, where is that from?

Reason I ask is I will be doing something similar but could only find a plastic tee made by doorman. I can get a brass tee from Home Depot but the specs say working temperature is up to 180 Fahrenheit. Which seems odd to me but the coolant gets warmer than that so I went with the plastic tee.

[highbrowed]

Originally Posted by houtan

Nice work!!

That Tee fitting that you used to splice the expansion tank drain to the heater line, where is that from?

Reason I ask is I will be doing something similar but could only find a plastic tee made by doorman. I can get a brass tee from Home Depot but the specs say working temperature is up to 180 Fahrenheit. Which seems odd to me but the coolant gets warmer than that so I went with the plastic tee.

Thank you, I'll dm you the link.

[frankies.slow128i]

Hey so I'm in the process of gathering parts for my 128i turbo 5.3 swap and I noticed you're running a stock cooling system, did you need to upgrade the radiator, how well does the LS cooling line up with the OE radiator?

[highbrowed]

Originally Posted by frankies.slow128i

Hey so I'm in the process of gathering parts for my 128i turbo 5.3 swap and I noticed you're running a stock cooling system, did you need to upgrade the radiator, how well does the LS cooling line up with the OE radiator?

The stock cooling system is fine for this application. I might upgrade to an all aluminum radiator in the future but the stock fan and shroud are unmatched compared to aftermarket alternatives. Another option would be to use an M3 radiator and fan, I believe it's a higher cooling capacity and I know the fan is higher wattage compared to the 135i.

[e80two]

Originally Posted by StevieJ2

Unfortunately I believe the E and F setups are different. Not sure what specifically, but none of the adapters I found go with an e series either.

https://pmcmotorsport-shop.com/produ...c-DCT-8HP.html

"Aluminum adapter enabling to mate (SWAP / conversion) the GM Chevrolet LS LS1 LS3 LS6 LS7 LS9 LT1 LT4 LSA LSX Vortec engine with the manual / automatic ZF (ZF Friedrichshafen) / Getrag gearbox from BMW.


BMW GETRAG DKG DCT GS7D36SG N54 S55 N55 7-speed
GS7D36SG - BMT 28 00 7 640 956 / 28 00 7640956
GS7D36SG - 28 00 7 585 538 / 28 00 7585538
GS7D36SG - 28 00 8 482 016 / 28 00 8482016
GS7D36SG - ABW 28 00 7 853 541 / 28 00 7853541
GS7D36SG - ABY 28 00 7 853 542 / 28 00 7853542
GS7D36SG - AC2 28 00 7 853 546 / 28 00 7853546
GS7D36SG - AC5 28 00 7 853 549 / 28 00 7853549
GS7D36SG - ADE 28 00 7 853 550 / 28 00 7853550
GS7D36SG - AEA 28 00 7 853 551 / 28 00 7853551
GS7D36SG - AEB 28 00 7 853 552 / 28 00 7853552
GS7D36SG - AEE 28 00 7 853 554 / 28 00 7853554
GS7D36SG - AEG 28 00 7 853 555 / 28 00 7853555
GS7D36SG - AEP 28 00 7 853 557 / 28 00 7853557"

[siado]

This will be a long shot, but do you think there would be room on the passenger side forward of the engine for a dry sump tank? Wondering where I could squeeze on in without resorting to the trunk.

[highbrowed]

Been a while since I updated, but I have just been enjoying the car. It's dead reliable and I haven't had to do anything since the swap except a set of plugs and an oil change.

One remaining issue I was having is higher IATs than I would like when sitting in summer traffic in South Florida, since the intake filter was unprotected in the engine bay. To fix this, I built a cold air intake system that draws air from the stock intake snorkels.

The intake setup was built using a Turner Motorsport E82 hot side intake duct, an Airraid "u-build-it" 4" kit, 4" K&N air filter, and a custom aluminum air box. After implementation, intake temps have dropped significantly, to around ~12°F above ambient.

I also created custom brackets which allow installation of engine covers from an E34 M60 V8, and installed an LSE90 coolant overflow tank to clean up the engine bay and get everything as OEM looking as possible.

[ShocknAwe]

Have room for 180* headers on it?

Looks outstanding. Very nice job.

[highbrowed]

Originally Posted by ShocknAwe

Have room for 180* headers on it?

Looks outstanding. Very nice job.

Unfortunately not, the steering shaft is the limiting factor. LSE90 does sell long tube headers that go around the shaft but I'm going turbo anyway soon so I stuck with the LS3 OEM manifolds for now.

Thank you, means a lot coming from you. We've been on this board together a loooong time.

[highbrowed]

Originally Posted by siado

This will be a long shot, but do you think there would be room on the passenger side forward of the engine for a dry sump tank? Wondering where I could squeeze on in without resorting to the trunk.

I would think so. Without the air box setup there's lots of room. I moved all accessories to the driver side with intention of putting a turbo on the passenger side.

[scratchgolf135]

If you're running the N54 Rad you should have room where the back half of the intercooler was (below the rad). I'm still N54 but I'm going water to air and have decided I can put an Accusump down in this space as it's roughly 5"x5"x24" of free space now.

[ShocknAwe]

Originally Posted by highbrowed

Unfortunately not, the steering shaft is the limiting factor. LSE90 does sell long tube headers that go around the shaft but I'm going turbo anyway soon so I stuck with the LS3 OEM manifolds for now.

Thank you, means a lot coming from you. We've been on this board together a loooong time.

Damn well I was sorta 25/75 between this and a S65 swap. Guess this is out of the question if long tube or 180* headers won't fit.

Thanks for coming back in and sharing man.

[highbrowed]

Originally Posted by ShocknAwe

Damn well I was sorta 25/75 between this and a S65 swap. Guess this is out of the question if long tube or 180* headers won't fit.

Thanks for coming back in and sharing man.

Long tube do exist but are out of stock due to popular demand. Should be back in stock within the next couple weeks as per Michael Page, the owner.

https://lse90.com/products/lse9x-ls-...LXzcOjZoZvaWJz

[ShocknAwe]

Originally Posted by highbrowed

Long tube do exist but are out of stock due to popular demand. Should be back in stock within the next couple weeks as per Michael Page, the owner.

https://lse90.com/products/lse9x-ls-...LXzcOjZoZvaWJz

Sorta a moot point if they don't fit though right?

[ShocknAwe]

Actually since your post I've been reading about this again. My biggest problem before was my feelings about stock LS sound. Just don't really like it. Found some LS swap vids with absolutely killer sound so let's say I'm back to 50/50 on LS vs S65. It's definitely less expensive by far and will be a far easier job for me in my garage. I'd like to have my E82 back up and running in 6mos or less.

Did you ever find a solution for cruise control?

What final drive ratio are you using?

Any thoughts on under hood temp control that wouldnt require louvres? I love your valve beauty covers. Would definitely want to look into a very unassuming BMW styled engine bay.

What was wrong with the stock engine mounts? I have IS mounts and really hated solid mounts, then again that was with the N54.

I read through your AC adventures. I see that's now as available through LSe9x.

Any custom things that aren't going to be made available? I'm not an engineer.

[ShocknAwe]

Talking with Michael from LSe9x later today hopefully