2.2 engine replacement project

[mrscalex]

Thought I'd already started a thread for this when I first had it. But can't find it. It's been so long waiting its turn and for the better weather.

Anyway, as per title it's a like for like 2.2 swap as the original is seized. It's not a bad car at all and should scrub up nicely.

Everything has been methodically disconnected over a period of some weeks.

The exhaust bolts were seized solid and I just cut through next to the joint on the manifold side in the end.

That was the most frustration inducing job. Followed by the ridiculous clip that locates the gearbox selector rod. And I made a hash of getting the prop shaft bolts undone too.

Anyway. Waiting at the tool hire shop for my brother in the van we've hired for umpteen jobs over the Easter weekend.

Here's some pics just before we pull the engine tonight.

 

[Low Rider]

This will an interesting thread

 

[spurs fan in a coupe]

good luck mate

 

[PHILIP BAXTER]

Good luck with the swap, hope it goes well.

 

[mrscalex]

Well it's out.

Naturally I had a fight as I was determined to extract it by removing/disconnecting as little as possible. And later put back a replacement engine bought with as much on it as possible. This, you must understand, was for the greater good and not laziness There is an almost complete lack of engine removal guidance for Z3s so I wanted to see if I could trailblaze a beginners guide. That will follow when I remove the engine from my 2.2 breaker as this was my practice run...

In particular I wanted to leave the exhaust manifolds on. Which it turns out is perfectly reasonable but I should have removed the steering column. Now I have to remove the steering column anyway as I wrecked it...

Other bits I should have removed were the gearbox crossmember (no idea why I thought it was a good idea to leave that on), the engine mounts and the nearside engine mount bracket.

I didn't get the angle of dangle right either and the gearbox kept on catching on the transmission tunnel. The £36 I invested in a load leveller saved me from complete humiliation though.

With the engine out I confirmed my working assumption. I don't like the look of the whole front end - subframe, steering rack, struts, sway bar, p/s cooling pipe etc. It's all too rusty. Which is strange as the rest of the car is solid. So it will have the fresh front end I built up for the previously abandoned project.

And I've been quoted £30-£40 from Bournes for shot blast and matt black primer powder coat of the front panel. Which I think is what the factory did as the inside of the front panel is usually matt black. I'll use a rattle can for the bits that should be coloured. I don't want to go overboard but I might just get the subframe and sway bar blasted and powder coated too.

And it makes sense to have all that removed at the point the engine goes back in and build it back up afterwards. That way the engine/gearbox really will slide straight back in. And the subframe can go in underneath straight after. That's clearly moving away from the remove as little as possible concept but the front end needs to come off now anyway.

Tomorrow we'll get the engine bay cleaned up and see how much attention that needs. With everything out it would be silly not to touch up any rust spots etc. I might even have to break out a rattle can and do a more extensive clean up. You will find many unresolved discussions on the internet regarding the exact colour/finish of engine bays. Titanium Silver has a very different under bonnet relative. I'll probably get it mixed by a specialist to match anyway.

A few pics now. The notes I kept tell me I spent 17 hours to get this far. I'd be dissapointed if I couldn't do it again in less time but in all honesty I'm not sure it would be drastically less.

 

[t-tony]

So, is that you in the last picture saying "That's a big hole" Rob?

Tony.

 

[mrscalex]

Yes that's me. Actually thinking that's a small hole to pull something that big out of. And it will get even smaller when I try to put something that big back

 

[mrscalex]

And I'm also thinking "I hate dismantling power steering circuits as the drips go everywhere and b*gger your drive up no matter how hard you try to catch them!"

 

[t-tony]

I can understand that mate, my drive is block paviours but is still a bi*** to keep clean.

Tony.

 

[Jack Ratt]

Nice work.

 

[Synclare]

Bet your neighbours love you Some serious dedication there

 

[mrscalex]

Bet your neighbours love you Some serious dedication there

My neighbours hate me. But when they get old one day pondering what they might have achieved with their lives before they were too old to do it I can add saving another little Z3 to the list along with numerous other stupid things that hopefully make me a lot less boring and stuck up my own ar*e than they

And it means I do some proper stuff with the little man. Who isn't really that little any more - at 13 he's now closing in on me at 6 foot. He was happy enough when it came out.

That said I do have some compunction and put the font end back on before I wound up. So it looks like a normal car from the outside again now. 5 minute job on a Z3

The engine is now also on the drive... I have to get that broken down into component parts today in the hope that makes it light enough to get the block to the dump. I was studying YouTube videos of how to do that when I came in last night. This guy's M54 videos are fantastic. He has a full series on stripping down.

View: https://www.youtube.com/watch?v=0x9RgACQTGA

 

[Ianmc]

Would make a nice car for your son when he is 17. I started working on my first car (triumph herald convertible) with my dad at 16, happy days!

 

[mrscalex]

This one was supposed to earn me some pennies back to offset the huge amount I spend keeping 3 other Z3s on the road around the family

But I've got a feeling I won't want to move it on after all the work. It has a potential life in Swindon as my Topaz Blue 2.2 is normally kept up in Swansea with my other half. But that would be just a tad extravagant to have a £3k car in each port. I wouldn't call myself hard up but neither have I got the money to really justify that

I think the insurance on my brother's 1.9 was quoted at £3k for my 18 year old daughter. A 2.2 was a firm no quote!

 

[Ianmc]

Insurance cost is always an issue for the kids. I worked most weekends and holidays from being 14 to buy my first car (£120) and pay for tax/insurance/petrol. Third party insurance kept me sensible on the road! Genuine petrol heads start young!

 

[mrscalex]

Insurance cost is always an issue for the kids. I worked most weekends and holidays from being 14 to buy my first car (£120) and pay for tax/insurance/petrol. Third party insurance kept me sensible on the road! Genuine petrol heads start young!

He's a member of the Under-17 driving club. So we've started already He's very adept at tootling his sister's C2 round the disused airfields

 

[mrscalex]

The engine bay has had a spring clean today. I'm using a new chemical.

It was only meant to be a quick clean to see what needed repainting. It was quick but I was really impressed with the £1.76 can of chemicals and the job it did. And the engine bay was nowhere near as bad underneath as I thought it was.

I'll get the expansion tank, washer bottle and the plastic on the left taken off when I go back and give it a more loving scrub.

I'll probably rattle can the chassis rails. And touch in the inner wings with a brush.

And the can of chemicals

 

[Jack Ratt]

That's a great tip

 

[Ianmc]

You've just caught the rust in time to easily treat, just need under bonnet paint to complete (holy thread jump)

 

[t-tony]

The engine bay has had a spring clean today. I'm using a new chemical.

It was only meant to be a quick clean to see what needed repainting. It was quick but I was really impressed with the £1.76 can of chemicals and the job it did. And the engine bay was nowhere near as bad underneath as I thought it was.

I'll get the expansion tank, washer bottle and the plastic on the left taken off when I go back and give it a more loving scrub.

I'll probably rattle can the chassis rails. And touch in the inner wings with a brush.

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And the can of chemicals

View attachment 53644

Just like my Scrubbing Bubbles, looks great now.

Tony.