M42 Installed.....Again

One of my reasons for upgrading to the M42 a few years ago was that I could conceivably replace an M42 a lot easier than an M10 and for considerably less money. I hadn't planned on having to replace the engine so soon, but it was a lot easier the second time.

Picking up where I left off, I bolted up a few more parts to the M42 before installation. These included the upper and lower intake manifolds, oil filter mount, the wiring harness, and the A/C compressor mount (not that I have A/C....yet).



Then I bolted up the transmission. This was decidedly easier than wrestling it into position from under the car.



Then I bolted the subframe to the engine, while still on the crane. Next, I dropped it to the ground, slid it under the engine bay and lifted it up through the engine bay. This was easily the smoothest and quickest engine install that I've ever done.



I still have to hook all the wiring, plumbing and accessories up, but this is progress.

A Few More Baby Steps

Just a few more things checked off the list. I installed the water pump and thermostat. 

Then I drilled and Helicoil'd four of the valve cover bolt threads. Yeesh. I also took the opportunity to repaint the valve cover and upper intake.

A once-over with the palm sander does wonders for detail.

The gap in the ribs on the upper intake is from an ill-fitting strut brace rubbing the intake.

All bolted up:

I also bolted in the coil-on-plug conversion plate along with the coils.

A Little More Progress on the New(ish) Motor

After finding a stripped valve cover thread in the newer M42's head, I drilled and tapped it for a Helicoil. 

Then I cleaned up the bottom end and bolted on the E30 upper and lower oil pans.

The studs are there for two reasons. First, they are really helpful for holding the gasket and pan in place while you're Loctite-ing your bolts. Second, some of the holes were mildly stripped, so I chased the threads a little deeper and installed the studs for more bite.

Next up, reinstallation.

Drastic Measures

I've been battling an intermittent overheating problem since I first installed the M42. I've replaced the thermostat twice, the radiator twice and the water pump once. I've flushed and bled the coolant system more times than I care to remember. Still, I keep getting air in the pressurized coolant system, which ultimately allows for a hotspot and boils the coolant, producing more air.

So, I'm replacing the only thing I have left to replace: the engine.

I'm guessing at this point that the head gasket is leaking and allowing air to get from a cylinder to the coolant system. So, I found another used engine. In all fairness, one of the reasons that I originally had for doing this swap was that a future engine swap would be easier. This is already proving out in that I found a cheap replacement motor that just happens to have a warranty on it's newly rebuild head.

So here is what I bought:



It's from an early E36, so I have to swap over the E30 oil pan and intake manifold.

So, let's get to work.



After wrestling with the engine from the top, I gave up and returned to the tried and true "from the bottom" drivetrain removal method. Here we are after a weekend of work:



A little cleanup is in order.



After a little cleaning and some touch-up paint:



I also started on refreshing a few gaskets on the E36 M42, just because it's easier to do most of these when the engine is on a stand.

New rubber timing chain cover outer profile gasket and tensioner plug crush ring.



Prepped to receive the E30 oil pan and intake, once they are clean: