[Vasitas]

Fitment of the exhaust

So yeah. Diffence between the RD28T and the M57 engine is the turbo sitting on the other side of the engine. That was a problem we thought. So we had to do some fitment to install it. So I asked my friend Robin to help me out. I have a semi-automatic welding machine that welds iron and metal perfect but no stainless steel. Robin has a semi-automatic welding machine which does. And he welded and fitted his own exhausts before so he was excited to help me out on the project. And he did a perfect job. We bolted the exhaust numerous times on and off to get that perfectly shaped exhaust. We used 60MM/2.36inch stainless steel tubes.

The exhaust tube starting from the turbo

Welded the new exhaust tubing onto the existing exhaust.

So we are very excited to find out how this engine will sound when we will get this engine started for the first time. :iconbana:

 

[Vasitas]

My next task is to install the inlet tubing, cooling tubes and intercooler tubes properly.

Normally everything would've been fitted on this weekend but the problem is some parts got delayed. Which really sucks since this was my last free weekend for the coming weeks. So I'll have to work nights now.

But I installed most parts which were already here to let you guys see how things are going to be.

Inlet tubing with original Nissan rubber hoses to get that nice OEM look. The stainless steel tube will get painted in black. Just like the rest of the parts. No fancy or flashy things under the hood.

Cooling outlet and inlet of the engine are on the wrong side. I could've modified the radiator but I chose to pull lines the opposite way. It sucks but we need to do this to prevent cooling problems and we don't want to return back to RD28T overheating moments haha. Barely finished but you'll get a picture of how it turns out.

 

[Benny Jahmin]

Exhaust looks good. I was wondering where it was going to fit.

 

[Warrior11982]

Great work... in my opinion, stealth look is the way to go. I would not like to get needless attention. Keep up the good work. It seems soon will be finished
When are you planning start it? Maybe the electronics are not installed so far, but I guess you already have all the “hardware” fitted

 

[Vasitas]

Exhaust looks good. I was wondering where it was going to fit.

This is how everybody does it over here. In Poland I've seen them do a straight pipe through the fender on the passenger side just before the passenger door. But I heard it could cause problem with the VNT and spool up. And because this car needs to be roadworthy and straight pipes aren't. And I don't like the noise of it too.

Great work... in my opinion, stealth look is the way to go. I would not like to get needless attention. Keep up the good work. It seems soon will be finished
When are you planning start it? Maybe the electronics are not installed so far, but I guess you already have all the “hardware” fitted

I have no idea, I hope around september somewhere. Electronics are getting done by Guy Ooms Diesel specialist. The total hardware is getting installed like 97% by myself.


_____________________________

Most parts of the inlet circuit, cooling circuit and intercooler circuit arrived so I can start installing them.
The more I'm busy with this project the more I realise this isn't a 1-week project. Guy Ooms (diesel specialist) does these swaps in around 100 hours if most things go perfect. But for me without a mechanical background it isn't simple. Most of the time I'm looking and looking at this engine bay figuring out small details and problems.
But most things are working out and I have 2 good friends (Jan and Robin) who come and help sometimes.

Ok, photo material says a lot more than 1000 words. Here is the beginning of the circuits.

The inlet pipes are 70mm diameter. Guy Ooms told me the turbo isn't made for sucking so I have to make sure the engine is getting enough air.

I ordered DO88 silicone hoses for the inlet and intercooler circuit. I used these on my daily sleeper Volvo and they are a premium brand when it comes to silicone hoses. No crap is getting installed on this car.

I need to trim and finish the hoses to make them fit. But it's hard to install everything directly because I need to measure so many things and make sure hoses don't rub. It's a slow job but it's kind of fun to do.

Inlet piping installed with selfmade brackets.

It was somehow a pain in the @$$ to find the right position of the stainless steel inlet pipe but it worked out. And then I figured out I didn't have a body lift and an extra 5 cm of space under the hood. So it didn't close haha! I had to get back to work and an hour later I found the right position and the hood closed perfectly. I moved the piping in front and a bit lower of the engine instead of mounted on the upperfront of the M57.

 

[Warrior11982]

Fantastic work...
I think your almost done with it... in a matter of a few days it will be fully funcional

 

[Benny Jahmin]

Must be getting close now?

 

[Vasitas]

Finished the project by 95%

Hello guys, had a hard time the last months so sorry for no posts at all. It has been very hectic, hard and I've had worries. I broke up with my girlfriend, my mother is very ill, I'm facing some medical problems myself, just bought a house... I haven't worked on the car for 3 months since it left to the specialist for the electronics but I took it home last weekend. I have a lot of pictures of the build yet to show but I can't find the motivation to upload them right now.

BUT I'm glad to say we got it running. I've finished the project by 90% by installing all the hardware myself. It has been an awesome adventure and great education to figure things out and to build everything custom. Besides the adapter plate and clutch kit nothing exists for this swap. I've put myself to the test because I've had no technical education whatsoever. All I had was the internet, my creative mind, friends to help my when I had a problem and my dad his workshop. I hope this encourages people to do a swap or something similar. It just takes common sense, a lot of preparation, time and courage. Everybody can do it.

The car went to the diesel specialist who did the electronics and now the car is equiped with a stage 1 ECU. It's running somewhere around 200-210HP and around 450-480NM. And I have to say it works great. Great power, great fuel economy and guys, the sound of this 3.0 24 valve inline 6 turbodiesel is just brutal. I've got 2 mufflers but to be honest, the thing is loud and sounds so aggressive and especially for a diesel it revs like a maniac!!! Here is a video.

Here is the sound of the car! FOLLOW THE LINK.

:arrow::arrow::arrow: https://youtu.be/5abc4RI-t1o

 

[Benny Jahmin]

Nice work. Looking forward to more pics and some videos of it in action

 

[Vasitas]

We are testing the engine for a week now and all I can say is just wow. I'm wondering why I didn't do this swap earlier... It's also fun to drive it in the rain, awesome to slide it around and pull handbrakes haha. And the sound. Everybody is stunned by the sound. Put on your speakers/headset and follow the link!!

https://www.youtube.com/watch?v=beGDCCmvJcI&feature=youtu.be

 

[Markos]

I just registered when I saw your thread about the M57 engine. I think your photos are broken? At least I can't see them. I like the build. Thinking of buying a Patrol (3th generation 5 doors) with a 3.3TD and replace it with a M57.

 

[heyhey]

Finished the project by 95%

Hello guys, had a hard time the last months so sorry for no posts at all. It has been very hectic, hard and I've had worries. I broke up with my girlfriend, my mother is very ill, I'm facing some medical problems myself, just bought a house... I haven't worked on the car for 3 months since it left to the specialist for the electronics but I took it home last weekend. I have a lot of pictures of the build yet to show but I can't find the motivation to upload them right now.

BUT I'm glad to say we got it running. I've finished the project by 90% by installing all the hardware myself. It has been an awesome adventure and great education to figure things out and to build everything custom. Besides the adapter plate and clutch kit nothing exists for this swap. I've put myself to the test because I've had no technical education whatsoever. All I had was the internet, my creative mind, friends to help my when I had a problem and my dad his workshop. I hope this encourages people to do a swap or something similar. It just takes common sense, a lot of preparation, time and courage. Everybody can do it.

The car went to the diesel specialist who did the electronics and now the car is equiped with a stage 1 ECU. It's running somewhere around 200-210HP and around 450-480NM. And I have to say it works great. Great power, great fuel economy and guys, the sound of this 3.0 24 valve inline 6 turbodiesel is just brutal. I've got 2 mufflers but to be honest, the thing is loud and sounds so aggressive and especially for a diesel it revs like a maniac!!! Here is a video.

Here is the sound of the car! FOLLOW THE LINK.

:arrow::arrow::arrow:

Is the ECU you're using a standalone unit or the original BMW ECU?

 

[Yasholes]

We are testing the engine for a week now and all I can say is just wow. I'm wondering why I didn't do this swap earlier... It's also fun to drive it in the rain, awesome to slide it around and pull handbrakes haha. And the sound. Everybody is stunned by the sound. Put on your speakers/headset and follow the link!!

Great build I'm keen to use this engine in my patrol also.

What exactly did you do to get past the ews system and what did you do to the wiring to make it all work?
Cheers.