Final Assembly

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 This page contains the details about the final engine assembly steps.  All details about the block and bottom end are contained in the separate bottom end page.

Cylinder Head

The cylinder head is a Metric Mechanic Sport Head that I purchased a year ago.  The head was wiped down but no work was done to it for this project.

I used an OEM S14 head gasket.  I was thinking about using a Cometic MLS gasket but decided it would be overkill for this build.  The S14 gasket works fine and this motor will not have the output of an S14 anyways.

The S14 gasket needs to be trimmed to fit the M10 timing cover.  There is also a piece that extends beyond the M10 head in the rear corner that I also trimmed.

The S14 has an extra oil passage on the rear corner that can be trimmed off.

The S14 timing cover is a little wider. The gasket needs to be trimmed to fit. I filed a new notch in the gasket to accept some gasket sealant.

The side of the timing cover gasket was cut to fit.
The head was installed using the S14 head bolt torque sequence.  Camshaft gear and chain tensioner were installed per M10 assembly instructions.

 

Upper timing cover and valve cover were installed. 

Starter

S14 starter (left) weighs 7 lbs. M10 starter (right) weighs 17 lbs.
I'm using an S14 starter.  It is a lot smaller and 10 lbs lighter than the M10 starter used on the E21.  You need to use the S14 rear support bracket since the starter is shorter than the M10.

The M10 starter is the original to my car, almost 33 years old.  I think it was time to replace it.

Throttle Bodies

Installing the Jenvey throttle bodies is a simple enough, if somewhat tedious job.  There are a lot of fasteners and a lot of tight places to work in.  Doing this work on the engine outside of the car was a real treat, it is never this easy working in the engine compartment.  I'm normally bent over the left front fender trying to work on these things without being able to see what I'm doing.

Jenvey 40mm ITBs bolted back onto intake manifolds. Vacuum distribution pipe is seen attached to the top of the intake manifolds.

Another view of the throttle bodies and the Jenvey throttle linkage.

Engine tipped on its side to install the air horns. It doesn't get any easier than this. Air plenum is a modified TWM piece.

Very tight working area installing the M6 screws that hold the air horns in place.

All four air horns installed. Note tight clearance with alternator.

Alternator

I'm using an 80 amp alternator from an E30 318i.  The E21 alternator is only 55 amps.  It bolts right up to the same mounting location as the M10 alternator.  You need to use the E30 mounting bracket and adjuster.  The 2002 water pump pulley is slightly larger in diameter than the E21 pulley.  I used the 2002 fan belt which is 10mm longer than the E21 belt.  This provides enough extra length to make the belt installation a lot easier.

Alternator installed. I used a 2002 fan belt that it 10mm longer than the E21 belt.

Side view of alternator and throttle bodies. Note clearances between the alternator and the oil filter housing and the throttle bodies.

There are only a couple millimeters of clearance between the alternator and the throttle position sensor.

Finishing Up

A couple shots of the engine just about ready to be taken off the stand.  Just waiting for the crank scraper to arrive so I can install the oil pan.

The crank scraper was installed along with the oil pan.  This is documented on the oil system page.

The next step was to prepare the engine for installation into the car.  I don't own an engine hoist because this is only the second time I have had the engine out of the car.  Instead I use a hand winch attached to a beam in my garage and an engine leveler.  The engine was taken off the stand and places on some 4x4 scrap on my garage floor to install the flywheel, clutch, starter, and transmission.

Engine being removed from stand.

Placing engine on some scrap lumber to finish assembly.

Flywheel installed. This is a slightly lightened flywheel that a friend gave me.

Clutch installed.

Transmission and S14 starter installed.

Ready to go back into the car.

 
Placing the engine back into the car consists of manipulating the hand winch and leveler as well as carefully rolling the car forward.  Not as easy as with a proper engine hoist but this is a lot cheaper and stores a lot better when not being used.

It's a pretty tight fit getting the engine and tranny into the car as a unit. Notice the cardboard in front protecting the front sheet metal.

Back where it belongs.

 

 

 

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This site was last updated 12/29/09