Prep the Car - Nash Motorsports
Contents
1. new ABS bracket as template drill 1 4 hole in wheel house and attach bracket using m8 bolt and nut provided WS New ABS Bracket Drilling hole in fender for ABS bracket JPG Nash Motorsports Page 17 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 44 Rebend brake lines and reattach to ABS modulator Be sure rear line has adequate clearance to the steering shaft Use a 18mm box end wrench as a bending tool to work the rear line e gt nt as n a CALLLETTTETE ABS installed JPG Brake lines reattached 2 JPG Nash Motorsports Page 18 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 45 Place clutch fluid reservoir on firewall and mark mounting hole locations see pic 46 Drill 1 4 holes for the clutch reservoir and attach using m6 button head SS machine screws Place bracket against sheetmetal edge Drill 1 4 holes and attach with m6 gt ee atts op booster mounting holes to bottom edge of he bracket Clutch Reservoir Location JPG Nash Motorsports Page 19 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 47 Attach Fuel Pressure Regulator to the bracket on the shock tower using m6 button head SS machine screws The attached picture shows an early fuel line routing Pictures of the actual routings were lost in a hard drive crash sorry 48 Run the fuel pressure line SS braided line rearward and tie strap to the ABS bracket pulling the fuel line as cl2. remove large rubber shifter grommet 58 Use Sawzall or saber saw to enlarge shifter hole 1 rearward Be careful not to cut into console when cutting out tunnel Remove console to eliminate this concern i s Start by drilling holes in yee saagcorners then use 29 g sawzall to cut out gt ue the tunnel a TEY ipi 4 Trim carpet along this i B e EES E ee I essere e line using utility knife re aca E s E about 1 4 Ti Be careful not to cut py eee at NE f wires running in area Trim Carpet JPG _ Tunnel Cut JPG Nash Motorsports Page 22 E36 LS1 Conversion Part 1 Prep the Car Ver 180ct05 59 Inside engine compartment cut battery tray as shown 60 Remove PCM mounting brackets in the PCM compartment ut shelf along line shown here Nash Motorsports Page 23 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 61 Cut edge of PCM access hole enough to allow fcar PCM to be installed into PCM mounting compartment ae ee E i SH es i ein AI pit EET ne Trim ahese edges omer to ala Efcar PCM to fit into PCM gt compartment Cut Edge of PCM Compartment JPG Nash Motorsports Page 24 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 62 If not already done Bumper trim JPG Nash Motorsports E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 Remove trim piece to get to main bumper bolts Bumper Bolts JPG remove front bumper cover a MEF A TR
3. 1 Conversion Part 1 Prep the Car Ver 18Oct05 Connect to pin Connect to BMW blk yel start wire 8 EEr D Attach to pin B on the 4 pin connector gt C100B G fal r C on the 4 pin connector gt C100H dk blu A n Fan 2 power 238 paker Fan 1 power s Connect to pin D of the 4 pin connector gt C100A dk grn fan 1 ctrl Connect to pin A on the 4 pin connector gt C100J dk green AC clutch x Connect to purple starter wire data link connector pwr Connect to C101G PCM batt Prunk Clol Ss Pnk uh cio A fak chasis Pale clo G Om MK cwl E Page 35 76 Install reworked braked pedal and bracket 77 Attach clutch line to barb fitting on reservoir 78 Attach steel clutch line to clutch master cylinder being sure it snaps into place past the retaining clip Loosen ABS modulator and move out of the way if you need more clearance to get to this fitting 79 Remove rubber hose from end of steel clutch line and screw the m10 to 4 flare clutch line adapter to the end of steel clutch line 80 Install Hydroboost brake booster and master cylinder 81 Attach booster push rod to the brake pedal Nash Motorsports Page 36 E36 LS1 Conversion Part 1 Prep the Car Ver 180ct05 82 83 Bend brake lines and attach brake lines to master cylinder Note the inboard line goes to the rear MC port 84 Fill brake fluid reservoir and bleed brakes 85 Test brakes for leaks by applying holding hi
4. Nash Motorsports BMW E36 LS1 Conversion Part 1 Rev 180ct05 Prepare the Ca Follow these instructions step by step and by the end your car will be ready for marriage to your LS1 powertrain While it is possible to complete this prep work in a weekend it is more realistic to plan on 4 5 good days to get everything ready It is best to print out these instructions in black and white Color is nice but it takes a long time and you will burn up a lot of ink lf there are any questions please call am here to help and want your swap to be a fantastic experience Sincerely Mike Collins 586 943 6385 1 Follow service manual instructions to remove motor and transmission 2 Remove evap canister 3 Using sawzall remove bracket shown in picture Grind sharp edges and paint bare metal Using sawzall remove this bracket Grind sharp edges and paint bare metal Nash Motorsports Page 2 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 Cut rubber PS reservoir return hose and supply hose close to the reservoir Disconnect high pressure line from PS pump Remove PS pump and reservoir Note some models use brackets welded to the body to mount the PS reservoir If you have these brackets remove them by cutting with a sawzall Grind away sharp edges and paint exposed metal surfaces NOOA Remove rubber bumper and attaching stud Remove PS brackets and plastic tie strap PS Bracket Removed 1 Nash Motorsports
5. Page 3 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 10 Remove high pressure line from PS rack Line from pump 11 Install power steering line adapter into rack 12 Leave return line attached to rack M ile E Ga i New Power l Steering High Line Pressure Adapter Power P Installed in Steering Rack PS Line with tape PS rack with adapter Nash Motorsports Page 4 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 13 Remove cruise control unit 14 Use sawzall to remove front cruise control bracket leave rear bracket in place AR TN Bee ri A Fe ieee 7 EF p Pad a tel tie a ey ie et a _ i b ur fae fs a iad ach EF id EG ae ares mt R Use sawzall to remove Tforward cruise control bracket Do not remove rear bracket Cruise control and bracket jpg Nash Motorsports E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 Page 5 15 Powerwash and clean engine compartment 16 Place vehicle in work area on jack stands 17 While not necessary removal of fenders AC condenser and entire front clip makes installation of the motor much easier and is highly recommended It probably takes about 2 hours to completely remove clip but believe me this is time well spent 18 Locater heater control valve next to brake booster and document how the lines are attached 19 Disconnect coolant lines and electrical wires and remove heater contr
6. Violet Grey Brown Green Black Grey Blue New wire Brown Yellow Brown Violet Blue Yellow Green White Green Black Yellow b Cut wires 1 10 leaving them about 18 long Note For wires connected to the Data Link be sure to cut these after the Data Link splice Nash Motorsports E36 LS1 Conversion Part 1 Prep the Car Ver 18O0ct05 Connected to Data Link No No Yes No Yes No No No No Yes No Yes Page 28 c Bundle wires 1 8 together cut to length and install the wires into the female 8 pin connector The pins are soldered onto the wires and then installed into the connector d Bundle wires 10 and 11 together and attach 2 pin connector using crimp splices ae O MM dha 488 Wire Harness 8 Wire Harness i from BMW AAR a From fcar PCM 8 Pin Connector Nash Motorsports Page 29 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 e Locate the large green wire key on power Pull this wire from the harness and leave as long as possible This wire will be used to power the new electrical center f Locate the large black yellow wire Pull this wire from the harness and leave as long as possible This is the Start wire coming from the ignition switch g Run the green key on wire and the black yellow start wire in a conduit with the battery wire that attached to the BMW electrical center Crimp a blade style connector on the green wire and on the bl
7. ack yellow wire It is best to put a male on one and a female on the other This will prevent the wires from being hooked up wrong ee Pa 4t ane pm f E a a This conduit contains the battery power eed to the the BMW electrical center he green key on power wire going to the new electrical center and the black m ellow start power wire going to the new electrical center aik BMW power conduit JPG Nash Motorsports Page 30 E36 LS1 Conversion Part 1 Prep the Car Ver 180ct05 65 Remove data link connector DLC from the fcar body wiring harness leaving leads about 12 long 67 Remove the glove box inside the car and mount the DLC in the back top of the glove box aww y a 4 IA tay DANAE PERE RS Pa eat D AARE E AEII ASA Wa i Di hy ON iy X uP A N b f p gt n aa N i bt ANY i PRAA AY v Ay A 4 ah Ree SA oe ae we ey Inside of Glovebox Nash Motorsports Page 31 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 68 Drill a 3 8 hole in the firewall to run the DLC wires through This hole should be located so the wires will come out below the battery tray Install rubber grommet in this hole 69 Use excess DLC wire to make jumper wires that go through the rubber grommet in the dash and connect the DLC to the engine harness power and ground Use crimp on connectors on each end of the jumpers to connect to the DLC and engine har
8. ee A ae Remove screws inside wheelhouse Bumper will slide off Page ii S 25 63 Remove lower radiator valance and cut using saber saw as shown Nash Motorsports Page 26 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 64 Prepare the BMW electrical harness a Find the fuel pump relay and locate the brown green attached to socket 87 Cut this wire leaving long enough to attach a crimp on eyelet connector and attach to a ground lug Relay Positions Mounted in the left hand rear corner of the engine compart ment the power distribution box contains 46 fuses and 15 re lay positions See Fig 2 Fuses 1 20 z ye Fuses 31 46 Fuses 21 30 Fuel pump relay Heater A C Blower relay 2 System main relay Rear defogger relay Oxygen sensor heater re ABS system relay lay ABS pump relay Horn relay High speed radiator fan re Taillight foglight relay lay Low beam relay A C compressor relay High beam relay Low speed radiator fan re Emergency flasher relay lay Relay Locations jpg Nash Motorsports Page 27 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 BMW Electrical Cont Find the following wires in the BMW wiring harness 1 AC Request Low Oil Level Tachometer Check Engine Generator Status Oil Pressure Temp Gauge Power Temp Gauge Ground 9 Backup Lights 10 Backup lights 11 Key on power 12 Start COND OBR ODN
9. er 18Oct05 33 Send brake pedal pedal bracket and switches to the following address to be reworked to accept the hydroboost pushrod Nash Motorsports 7315 Greeley St Utica MI 49317 34 Remove front and rear brake lines from ABS modulator leave master cylinder lines attached Remove ABS modulator and clean area behind modulator 35 Cut ABS brackets using sawzall Paint exposed metal A bA Cutting ABS bracket jpg Nash Motorsports Page 14 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 37 From center of brake booster hole measure straight down 6 1 4 and outboard 3 4 Drill 3 8 hole through firewall at this location AE 38 From inside car install M8 x 25 bolt through hole just drilled 39 Install 2 washers provided over bolt to act as shims see pics Use 2 M8 washers for shims ABS bolt through firewall jpog ABS bolt with shims jpg Nash Motorsports Page 15 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 40 Cut the legs off of the rear ABS bracket and drill out existing hole to 3 8 41 Attach rear ABS bracket to firewall ghia af s i 7 a te fhe v4 7 E 1 Fee ABS bracket installed JPG Nash Motorsports Page 16 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 42 Attach new ABS bracket to ABS modulator Place ABS into rear bracket and allow front bracket to rest on frame rail Be sure rubber isolators are fully seated in rear ABS bracket 43 Using
10. gh force on the brake pedal for 10 15 seconds then inspect each fitting at the master cylinder and ABS modulator for any signs of leaking 86 Slide small diameter firesleeve onto steering shaft to protect rubber sleeve 88 Slide large diameter firesleeve onto steering rack flex coupler THAT S IT FOR CAR PREP Nash Motorsports Page 37 E36 LS1 Conversion Part 1 Prep the Car Ver 180ct05 Revisions OlJanO7 Modified brake line installation to just rebend and attach to master cylinder Do not cut and flare Nash Motorsports Page 38 E36 LS1 Conversion Part 1 Prep the Car Ver 180ct05
11. ness gt wires coming from E engine compartment grommet Run DLC power ground and a42 communication wires through Nash Motorsports Page 32 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 70 Install new electrical center EC onto battery tray as shown in picture Mount fuse box using 10x3 4 SS sheetmetal screws Use 9 64 drill bit Nash Motorsports E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 mee M6 bolts Use 1 4 Porin bit FA holders using 6 SS sheetmetal screws Use 3 32 drill bit gt Mount relay box using Page 33 71 Connect the ground black wire to the ground terminal on the battery tray 72 Cut long black wire to length and connect to ground wire coming from the DLC 73 Connect DLC red jumper wire to the bullet connector coming from fuse 7 74 Large power feed connects to the middle battery terminal Do not connect until you are ready to start the motor 75 Run the long fan wires F1 amp F2 along the edge of the fender up to radiator area Secure with tie straps pe A Do not connect the main power wire until you are ready to start the car Connect main Nash Motorsports Page 34 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 For your reference this is a schematic of the new electrical center crude but accurate wire labeled AS Connect to BMW green key on power wire Nash Motorsports E36 LS
12. ol valve Control valve will be relocated to passenger side of radiator Heater Control Valve note if you have dual zone climate control your valve will have 3 ports In this case take a picture so you are sure to connect correctly after valve is relocated Heater control valve jpg Nash Motorsports Page 6 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 20 Remove insulation from firewall and tunnel 21 Using a combination of the existing BMW heater hose and new hose rout heater hoses along top of tunnel and attach to AC line with tie strap Leave hoses long enough to reach the passenger side of the radiator as this is where the heater control valve will be relocated Heater hose routing jpg Nash Motorsports Page 7 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 22 Using hammer modify tunnel to give clearance for the transmission Hammer tunnel jpg Tunnel finished jpg Nash Motorsports E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 Page 8 23 Use sawzall to remove shifter mounting bracket located in tunnel behind shifter hole 7 b 6 6 Remove Insulation Shifter bracket jpg Nash Motorsports Page 9 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 24 Inside engine compartment remove brake lines from master cylinder disconnect clutch fluid line from brake reservoir 24 1 If you have a 92 94 car then unplug sensor from booster and install 380 ohm re
13. ose to the fender as possible then down next to the frame rail and back to the pressure line on the BMW the pressure line is the one with the fuel filter Do not connect yet 49 If you have not replaced your fuel filter recently do it now This motor requires lots of fuel during and a dirty filter will starve the motor 50 Run the fuel return line from the BMW forward to the fuel pressure regulator Run this line next to and below the fuel pressure line Tie strap the lines together and keep as close to the fender and rail as possible Do not connect at this time We want to be sure there is good clearance to the headers before cutting the line to its final length Return a Actual routings are more like he sketched in lines Existing BMW fuel return line Fuel Regulator and Lines JPG Nash Motorsports Page 20 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 50 1 Remove power steering pressure line and install m14 to 6 metric adapter Pressure Line MME ALLL PS Pressure line at rack jpg Nash Motorsports E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 Page 21 51 Remove steering rack 52 Remove front sway bar and control arms 53 Remove front cross member 54 Leave struts knuckles and brakes installed 55 Remove motor mounts from front crossmember and loose install new M3 mounts 56 Tighten mounts just enough to engage the antirotation tabs 57 From inside of car
14. sister 25 Inside car remove driver side kick panel hush paned knee bolster cover and knee bolster so you can get to the brake pedal brackets Apea Ra LA gt 1 Ff E A p s A ea ain A 1 remove hood release 2 turn kick panel screw 1 4 turn p to release Hy Panels jpg Knee bolster jpg Nash Motorsports Page 10 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 26 Remove 4 nuts from brake booster studs 27 Remove brake booster push rod from brake pedal 28 Remove master cylinder and booster from car Booster Studs Nuts Nash Motorsports Page 11 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 29 Remove retaining clip from clutch master cylinder and remove clutch line from clutch master cylinder 30 Reinsert clip into clutch master a A ia Remove clip and remove clutch line from clutch master cylinder Clutch Line jpg o Nash Motorsports Page 12 E36 LS1 Conversion Part 1 Prep the Car Ver 18Oct05 31 From inside of car unplug electrical connectors at the two switches on the pedal bracket 32 Remove brake pedal clutch pedal bracket and switches Clutch pedal brake pedal clutch master cylinder and l brake switches are all mounted to this bracket Remove everything as an assembly Unplug switches Brake switches jpg Nash Motorsports Page 13 E36 LS1 Conversion Part 1 Prep the Car V
Download Pdf Manuals
Related Search