Need help building a parts list for a 3.2 engine swap.
 

Will be picking up a 1987 58k 3.2 engine in a couple of weeks to swap out my 1987 171k 3.2 and thought I'd start working on a parts list now. Will be mating engine with my G50 tranny.

I already know the fuel line needs work so I'll be sending it to Amazon Hose to be redone using braided stainless lines. Other than that I'll be checking all the rubber and vacuum lines and replacing as needed.

While the engine is out what else should I do? (breather gasket, t-stat o-ring, etc.) I don't want to go nuts replacing everything but would like to take care of the usuall suspects while I'm at it.

Though I'd go ahead and place a parts order for the must haves now and work on the options list.

Suggestions appreciated.

Thanks!

Mark

some ideas from my top-end thread here:

http://forums.pelicanparts.com/porsche-911-technical-forum/425027-3-2-3-4-top-end-rebuild.html

I don't know that you'll have much difficulty with this. Its like taking the engine out and putting it back in! :)

I'd check:

Oil tank hoses- lower S hose, upper hoses that connect throttle body and engine case breather to the tank. All of these get hard with time and will leak if you don't reinstall them in the same orientation as they came off.

Fuel lines- not only the one under the intake manifold, but behind it- the one that connect the fuel rails at the rear. Also check the tiny elbow line that connects to the vaccuum diaphragm at the back of the engine.

Replace oil pressure warning light sender and case thermostat o-ring if they show signs of leaking. These are common leak areas on every engine.

Check intake manifold gaskets for leakage as long as the engine is out. The barrel nuts are notorious for coming loose.

Check timing chain boxes and camshaft seals behind them for leakage.

Check crankshaft seals for leakage- do not replace if they look good.

Check oil cooler for leakage at mating surface with engine case

Adjust valves while the engine is out of the car- MUCH easier.

Check condition of camshaft oil feed lines and chain tensioner supply lines

Check condition of wire harness for alternator. THis harness tends to get hot and cooked.

Clean idle control valve

Check condition of flywheel/clutch reference sensors. If the wire sheathing shows signs of cracking, you might as well replace them (witht the BMW equivalent- do a search) and hold your breath because they're kind of expensive ~$100 each I believe?

Check cyl. head temp sensor. Single wire sensor should be replaced with updated 2 wire sensor.

Check transmission input shaft seal and output flange seals. Check condition of guide tube, replace if scored.

Check your clutch housing and release bearing for wear. If the clutch housing contact surface shows a lot of scoring or heat marks (bluing) you may want to replace. I have a used clutch housing in good condition if desired. Make sure release bearing ears are in good conditon and bearing spins very freely.

Check condition of clutch release fork cross shaft parts. You may have to replace some bushings, bearings or shafts, depending on what type of shaft is installed in your car. There are three types- original factory (needle bearings in clutch fork), aftermarket (bronze bushings in clutch fork), or factory update (plastic bushings in fork, needle bearings on ends of shaft in bellhousing).

Check condition of clutch slave cylinder. Replace if shows signs of leakage from pushrod boot

Check condition of bushings in throttle linkage bellcrank on transmission.


How's that for a start? :)

Kevin, Awesome list!

Much appreciated!

I just wish you lived closer to me, I would love to come over and help - watch the engine swap. What do you think one weekend for the swap? :)

Picked up engine on Wed - Thanks Scott!

Nice fit in the Mountaineer

http://forums.pelicanparts.com/uploa...1220620307.jpg

Engine removal team - Thanks guys

http://forums.pelicanparts.com/uploa...1220620414.jpg

Pelican Carnutzzz on left, me on right in the inappropriate engine lifting attire.

http://forums.pelicanparts.com/uploa...1220620553.jpg

I'd switch out to monoballs - rear trailing arms - much easier to get to with the engine and transmission out. I would also replace the rear shocks to Bilstein sports while the engine is out - and replace the engine sound pad.

I'd also send out your fuel injectors on the 58K engine - witchhunter or cruzin to get them serviced - again - much easier while you have the engines out.

Thanks Jeremy - Got Witchhunter on my list to get the injectors serviced. Sound pad and bilsteins have already been replacedl.

Will be sending engine tin, fan housing and valve covers out to be powdercoated.

The purchase of this.......

http://forums.pelicanparts.com/uploa...1220794209.jpg

Has resulted in the re-prioritazition of pending projects around the house with the honey do's rising to the top before I can "touch" the engine. This is the first (replace rotten deck) we are hosting a wedding party next month.....

http://forums.pelicanparts.com/uploa...1220794564.jpg

In the meantime, under the cloak of darkness, I plan on pulling the injectors to sent to WitchHunter, the fuel lines to send to Amazon Hose, and the fan housing, tin and valve covers to send to the powder coater :D

Later, gotta go work on the deck. SmileWavy

The good new is: The deck is almost finished.

The bad new is: She wants the carpet upstairs replaced with hardwood flooring before the engine goes in. Yes dear:p

http://forums.pelicanparts.com/uploa...1223152194.jpg

Progress pic:

http://forums.pelicanparts.com/uploa...1226275788.jpg

you have discovered one reason why people rent storage units to do a motor rebuild

Looking good, deck is not to shabby, wouldn't want you on channel 5 with a deck collapse they always highlight!

Wow, that looks great!

OMG, how many hands do you have Mark?

Final Parts List:

Stainless bolts & gaskets for Muffler/ Cat Bypass/ HE
Stainless 6mm bolts for engine tin
Powdercoat tin and fan shroud
Pilot Bearing
New Flywheel bolts & bolt socket
Resurface flywheel
Send fuel injectors to Witchhunter for cleaning & benchtesting
Send carrera fuel line to Amazon Hose (Tampa) for braided stainless rebuild
Breather hose Gasket
Oil pressure switch (idiot light)
Thermostat O-ring
Oil cooler seals (3)
Cam and tensioner oil lines & sealing rings
Front intermediate shaft cover o-ring
Replace speed and reference sensors with cheaper BMW 12-14-1-708-618-M14
A/C and Alternator belts
Gasket set
Plugs
Distributor cap & rotor
Sport engine mounts
Oil filter & drain plug seals

Total tab: $600 excluding powder coating/ fuel line rebuild / and injector cleaning

Thanks for all the suggestions!

I don't think Mark's wife has let him sit down on the couch once since that engine made an appearance. I know I haven't seen the guy. Have you? Anyone? Has he been replaced with a Stepford Husband?

She was out of town this weekend......that's how the fan got did! :D Of course, that was after my assignment: install a new oven - ours crapped out. This on the heels of the new deck and a new roof installed 3 weeks ago. Fortunately, insurance paid for that! I swear, we are having to rebuild this house. SmileWavy

Clutch beginning to slip, therefore new clutch added to engine swap project.
Additions to parts list:

Rear Main Seal
P234 Seal Installation tool
G50 Main/output shaft seal
G50 shift shaft seal
Pressure plate
Spring centered clutch disc
Through out bearing
Guide tube
Shift fork operating shaft and bushing kit
Clutch slave cylinder
Chain cover gasket kit