Metric Mechanic m42 and m44 Engine Booklet

Metric Mechanic M42 M44 Engine Series One o Metric Mechanic’s NEW Engine Series

Introduction Otenthe Otenthe4 4Cylind Cylinder erBMWs BMWs are are overs oversha hado dowed wed by their their 6 Cylindercousinsothesame model.Forexample,the1990 318is 8is can can get get over over-l -loo ooke ked d in avorothe325iorM3.The same same goes goes or or the the 318ti 8ti and and 1.9 liter Z3. But at Metri etricc Mech Mechan anic ic, , we look look at the the 4 Cylindersasjuniormodelso theMcars.TheE30318iuses lighterscaleddowndrivetrain componentsthantheE30M3. TheE36318ti&Z3continue this this them theme e thro throug ugh h smal smalller morecompactbodies.Allthe 4 cyl cylinde inder r car car model odels s hav have lightw lightweig eight ht bodies bodies with lightlight weigh weight t engines engines, , transm transmissi issions ons anddierentials.Weightisnot onlytheenemyoacceleration butalsohandlingandbraking. The The M42 and and M44 DOHC DOHC (doubleoverheadcam)enginesused (doubleoverheadcam)enginesusedinthesemodels inthesemodels haveexcellentpowerpotential.Currently,our2100 RallyEngineisgoodorjustover200HPandcan ripthroughthe1/4milesin1 ripthroughthe1/4milesin14.5sec.at98mph 4.5sec.at98mphin in anE30318is.FASTora4banger! The The powe powerr not note (the (the soun sound d the the eng engine ine make makes s whenitapproachespeakcylinderlling)comeson at4300rpmsandtheenginegeneratesverystrong pulltoits7700rpmredli pulltoits7700rpmredline.Eve ne.Evenbelow nbelow 4300 the

enginehasadecentamountotorquewhichmakes itagreatdailydrivercapableo30mpginhighway use.NoworacloserlookatthenewMM“Baby M3KillerEngine”.

Anatomy o our M42 Engine Metr Metric ic Mecha echani nic c 2000 2000 Spor Sport t Engi Engine nes s use use our our lightweightorgedalusilpistons lightweightorgedalusilpistonsalongwith alongwiththestock thestock connectingrodand81mmstockcrankshat.Metric MechanicRallyEnginesaredesignedandbuiltto betheasteststreetenginesthatwesell.Theyare basicallyullraceenginesde-tunedbydroppingthe compressionandcammingslightly. Theinterna Theinternalsarebee lsarebeeedupbyagain edupbyagainusinglig usinglightht weig weight ht but but strong strong org orged ed alusi alusil l pist piston ons s as well well as orged4340ChromeMolycustomrodso“H”or “I”Beamdesign,and “I”Beamdesign,and88mmorged 88mmorgedsteelcrankshats. steelcrankshats. These These comp compon onent ents s great greatly ly exten extend d the lie lie o the engineandmakeitvirtuallybulletproo. 2100 Rally engine on the hook ready or installation Copyright© November November 2006 by Metric Mechanic Inc™ 505 East Main, Richland, MO 6555 6 PH: 573-765-1269 FAX: 573-765-421 573-765-4216, 6, Email:hiperformancebmw Email:[email protected] @metricmechanic.com, m, www.metricmecha www.metricmechanic.com nic.com

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2100 Rally Acceleration Graph 1991 E30 318is with Metric Mechanic 2100 Rally M-42 Engine

“Baby M3 Killer!” Weight Weight is the enemy of acceleration, braking and handling. The M42 engine is already light - but we make it POWERFUL! The Metric Mechanic gang couldn’t stop talking about this car! Our comments were: “More power than the factory ever intended!” “How many cars can do almost 100 mph in a 1/4 mile and 30 mpg in highway driving?” “The Lotus of BMWs, a powerful engine coupled to a lightweight body and drive train.”

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Copyright© November 2006 by Metric Mechanic Inc™ 505 East Main, Richland, MO 65556 PH: 573-765-1269 FAX: 573-765-421 573-765-4216, 6, Email:hiperformancebmw Email:[email protected] @metricmechanic.com, m, www.metricmech www.metricmechanic.com anic.com

Anatomy

of the

M42/M44 2000 Sport Engine

Lightweight yet High Quality Strong Internals

Description Top:the2000Sportbottom endcomponentsincludeeither the M42 81mm orged steel crankshatortheM4483mm castcrankshat. Shown right: M42 rods at 610grams,optionalM44rods at 540 grams on the right. Bothare140mmlong. LetCenter:ourMMslitted lightweight orged alusil pistonsat310gramsandtapered wall wrist pins at 89 grams. The ring pack uses a 1.5mm Moly compression ring, a 1.5mmironscrapperringand a3mmthreepieceoilring. MM M42/M44 2000 Sport Bottom End Components (see be low or M44 crankshat)

Let: M44 2000 Sport Engine crankshat Right: M42 2000 Sport Engine crankshat

M42/M44 Cranks Thecrankshatontheletisusedinthe‘96,1.9 literM44engine,has4counterweightsandweighs 28.5 lbs.Thiscrank isusedinOBDIIenginesand employsa60toothtimingwheelthat’sattachedto the4thcounterweight.Thecrankontherightisthe pre’96M42orgedsteelcrankshat,has8counter weightsandweighs29.5lbs.

Piston and Rod By lightening up the reciprocating mass, an engine’s longevity can be greatly increased. In a Sport Engine, this is done by reducing the piston and pin weight by15%overstockwhich inturnincreasesrodlie becauseitisnotbearing somuchweight.Alsoit reducestheloadonthe rodbearingsandcrankshat. With the M44 1.9 liter rod and MM Sport piston shown to the let, the reciprocating mass is only 965 M44 2000 Sport Piston Rod Assembly grams.Butwithastock M42, 1.8 liter rod, the massis1015grams-50gramsmore!Usingthe1.9 literrodisaneectiveoptiontowardsreducingthe reciprocating mass in an M42 engine. These rods haveabearingcapthatmeasures.275”(7mm)atthe thinnestpoint.Wechecktheirconditioncloselyor “outoroundness”becausethethinbearingcapcan causethebigendotherodtoknockoutoround. Onceoutoround,therodbearingcapwillusually tlooselyontherod,whichleadstoatigue.

Copyright© November 2006 by Metric Mechanic Inc™ 505 East Main, Richland, MO 6555 6 PH: 573-765-1269 FAX: 573-765-4216, Email:[email protected], www.metricmechanic.com

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M42, M44 Pistons Decades o Experience & Research have led to MM’s Piston Designs

Let: M42/M44 2000 Sport Piston or use with the stock rod Middle: A 2100 Turbo Piston used with our MM “H” Beam Rod Right: The 2100 Rally piston used with MM Ultralite “I” Beam Rod

How MM Pistons Greatly Extend Engine Lie! A high quality properly designed orged piston, morethananyotherenginecomponent,cangreatly increase the lie o a High Perormance or Race Engine.Enginelie,iscurtailedbytheuppercompressionringhammeringouttheringgrooveand partsatiguecausedbyaheavyreciprocatingmass. Aorgedpistonis40%strongerandcanbemade 15%-20%lighterthanacastpiston-whendesigned properly. Although a orged piston is the perect solution,averageorgedpistons(notours)dohave disadvantages. Their expansion rate is 35% - 50% morethanacastpistonandrequires.0040”clearanceormore.Thismuchclearancecreateshighoil consumption(250-500miles/quart)andcausesthe pistontorattleoncoldstart-up. Considerthisinlightotheactthathighrevving heats up the piston, requiring more cylinder wall clearancetoaccommodatetheexpansion.Whenwe begandevelopmentoourHiPerormanceEnginesin 1984,wequicklyunderstoodthebenetsoswitchingtotheForgedAlusilPiston.Theseearlypistons weregraphitecoated to reducecylinder wall scuing.Duringtheenginebreak-inperiod,thecoating eectivelyworeo.Manysuchengines,underhard use,arestillperormingwithover200,000mileson them.Despitethissuccess,weeltcertainthatthere mustbeanevenbetterwaytoachievetighterpiston tocylinderwallclearance.

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Metric Mechanic Slitted Pistons Thenintheearly‘90s,wecompleteddevelopment o our “Slitted Piston” technique which involves machiningahorizontalslitintothepistonjustunder theoilringgroove.Thisslitkeepspistoncrownheat romtranserringdirectlytotheskirtbyconducting itinitiallytothequitemassivepinbosswhichacts like a heat sink. This interruption along with the longertraveledpath,helpstheheatdissipate;allowingorcoolerskirtsthatexpandless.ThisMMslit alsoreducestheexpansionrateoourForgedAlusil Pistonrom35%toonly5%overthatoastock pistonandistheprinciplereasonorourtightclearances.Generally,werun.0020”-.0025”clearanceon ourSportEnginesand.0023”-.0028”ontheRally Engines.Thiskeepsoilconsumptionlowandpiston rattlingtoaminimumoncoldstart-ups.

Metric Mechanic Boosted Pistons AprimaryconcernwithBoostedenginesispiston meltdown. In order to avoid piston meltdown we increasethecrownthicknessby2mm,lowerthetop ringgroove,anduse4mmwidehighradialtension oilrings.Thepistonpinwallisthickeroradded strengthanditweighs105grams.Thetotalpiston andpinweightisapproximately90gramsmorethan aRallypistonusedinanormallyaspiratedengine.

Copyright© November 2006 by Metric Mechanic Inc™ 505 East Main, Richland, MO 65556 PH: 573-765-1269 FAX: 573-765-4216, Email:[email protected], www.metricmechanic.com

M42/M44 Cylinder Head & Components Ported Head, Surace Turbulence Parts and Assembly Components

M42 Head with Metric Me chanic modications, ready or nal assembly. Shown let to right is an Hydraulic Liter Bucket, “Bee Hive” Valve Spring topped with Retainer, a Viton 6mm Valve Guide Seal with 6mm Keepers and Spring Perch, Manganese Bronze Valve Guide shortened to 6mm and a pair o 6mm Surace Turbulenced Intake and Exhaust Valves

Tour o the MM Cylinder Head Currently our M42/M44 heads fow 6% over the stock head. Pre ’93 M42 heads are converted rom7mmto6mmvalvesoraddedfowandlighter weight.Ourshortervalveguideincreasesfowover thehighsideradiusotheport.Seatsaremachined withthreeselectseatanglesdeterminedduringfow benchtesting.A 45°angle machinedinto theseat matches the valve head diameter. We also modiy theintakevalveback-cutangletoincreasefow.And weaddourpatentedsuraceturbulenceconcentric groovesto the valve itsel. For over 16 years, this treatmenthasproventoincreasefowatlowlits. Anaddedbenetisthattheyhelpatomizeuelby tumblingairfowoverthevalvesuraceandpulling uelparticlesothebackothevalve.

MM 100mm Head Bolts Weuseaspecial100mmlong socket head bolt. The stock torquetoyieldheadboltsare 90mm long. We torque our headboltsdownto64t.lbs. Theselongerboltsspreadthe load along the cylinder wall toreducewalldistortionand unliketheactoryheadbolts, theseboltsarere-usable. Let: MM 100mm long Socket Head, Head Bolt Right: Stock 90mm long Torx Head, Head Bolt


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M42 Sport Cam & Valve Train Components Comparing Intake and Exhaust Cams used or a Broad Power Band

M42 Sport Cams 258°andtheShrickat256°-amere2° OnanMM2000SportEngine,wecam advantage.Butanenginetakesinmost uptheintakeside(258°Duration/11.15 oit’sairwhenthecamhastheintake Lit)quiteabitmorethantheexhaust. valve open to .300” lit or more. Due Usingahotterintakecam,increasesRPMs toasterrampspeeds,ourcamhas124° andenhancestopendperormancewhile durationversustheShrick112°duration keepingthestockexhaustcams,maintains at.300”lit.Byhavinganadditional10% themidrangeandbottomendtorque.In moredurationatthenoseothecam,the theend,thiscamcombinationmakesor enginewillcontinuetomakepower10% anenginewithabroadpowerband.See higherinRPM.Also,alargerenginewill camchartlowerlet. needmorecamdurationandlit.A10% larger engine will need 10% more nose M42 256° Shrick Cams durationonthecamat.300”littohit TheShrickcamsetshownlowerright thesamepeakRPMpoint. isbasicallyanE36M3intakecamcopy. In the past, most manuacturers ran thesamecamontheintakeandexhaust Comparing the MM Sport Cams side. But, when the ‘95 M3 came out, with Shrick Cams BMWchosetoruntheirintakecamwith On the surace,by simplycomparing moredurationandlitthantheexhaust intakedurationat.005”,ourcamdoesn’t cam.Theyusedanintakecamwith256° lookthatmuchhotterwiththeMMat durationand10.35mmlit(sameasthe

Metric Mechanic

Sport Cam for the M42 Engine 258° Intake

Shrick 256 Cam for the M42

228° Exhaust

Engine

256° Intake

256° Exhaust

.005

258°

228°

.005

256°

256°

.010

246°

216°

.010

242°

242°

.015

242°

212°

.015

236°

236°

.020

238°

206°

.020

232°

232°

.050

224°

188°

.050

215°

215°

.100

202°

168°

.100

194°

194°

.200

166°

128°

.200

154°

154°

.300

124°

76°

.300

112°

112°

.400

64°

---

.400

30°

30°

Lift

.439” 11.15mm

.356” 9mm

Lift

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Shrick) but it also had25°oVANOS addedtotheintake cam. And they usedmildera235° exhaust cam with 9.7mm lit along with VANOS to increasethelowand midrangetorqueo theengine. So by running twodierentlobes where the intake cam is larger by about 15% over the exhaust cam, theenginedevelops a much broader powerband.Thisis alsowhatwedo.

.408” .408” 10.35mm 10.35 mm


M42 Sport Cam & Valve Train Components Upgraded Valve Train Components

Metric Mechanic - M42 Sport Cam Timing Map Intake Cam - 258° Dur. / 11.15mm Lift at .005” - Opens 10° BTDC - Close 68° ABDC Exhaust Cam - 228° Dur./ 9.0mm Lift at .005“ - Opens 41° BBDC - Close 7° ATDC Valve Opening During Overlap at TDC ...........................Intake .020” (.5 mm) .......................................................................................................Exhaust .015“ (.4 mm) Intake Cam - 258

TDC

Exhaust Cam - 228

Intake Lift

Intake Opens at 10° BTDC

Off Seat .020” ATDC

I n t a

k e

a

h x

s t

u

E

Exhaust Lift

Uses Hydraulic Lifters

Exhaust Closes at 7° ATDC

Metric Mechanic Bee Hive Spring & Retainer

Off Seat .015” ATDC

Intake Closes at 68° ABDC

No Valve Adjustment

MM “Bee Hive” Valve Spring with Lightweight 6mm Retainer and MM Heavy Duty 35mm Liter Bucket

Exhaust Opens at 41° BBDC

BDC

MM Heavy Duty Liter Bucket Our 35mm Liter Bucket has a harder nitrided crown makingitmorewearresistant. The liter spring is stier (see spring on let in Photo) to reduce literbleed-downandhelpthe litertrackthecamproleat higherRPMs.Whenanengine exceeds150,000milesandit’s rebuild time, wesuggestconsideringnewhydraulicliters.

TDC BDC BTDC ATDC BBDC ABDC

Top Dead Center Bottom Dead Center Before Top Dead Center After Top Dead Center Before Bottom Dead Center After Bottom Dead Center

Metric Mechanic’s use o the “Bee Hive”isapreerencethatevolvedouto experience with three previous springs choices.Becausespringrateisverycriticalinmakingthehydraulicliterworkat highRPMs.Whenusingcamswithhigher litsandasterrampspeeds(likeourcam designs) we are continually researching orbettersprings. Our “Bee Hive” springs and retainers are 25 grams lighter than the stock dual spring set-up. The 6mm retainer weuseismuchstrongerthantheBMW actory6mmretainer.Forinstance,our 6mm retainer can take up to a 310 lb. loadbeorethekeeperspullthroughthe retainer.TheactoryBMW6mmretainer ailsat185lbs.Wehavetaped amissed shitwherethetachwasjustshyo9,000 RPMwithnoincidentobentvalves.

35mm Lifter Buckets Comparisons MM Lifter

Stock

Nitrided Heat Treated

Heat Treated

54c

48c

Crown Thickness

.0957”

.0933”

Wall Thickness

.039”

.035”

Lifter Spring Wire Diameter

.038”

.031”

Crown Treatment Rockwell Hardness (C-Scale)

Shows the hydraulic liter and spring removed rom the liter bucket. MM to let, stock to right.


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Anatomy of the M42 2100 Rally Engine Rally Engine Part Descriptions

2100 Rally Crankshat, Pistons and Rod Bearings

MM’s2100 Rally engine is builtwithan88strokecrank, chainsprocket,harmonicbalancer hub, plus larger crank bolt&washer.Rodsarelight weight orged 4230 Chrome Moly Steel, shot peened and ully CNCmachined. Shown hereare525gram“H”beam rods.MMUltralite“I”Beam Rodweighs475grams-stock rod610grams.Pistonsare310 gram orged Alusil (13% siliconcontent)310grams.Stock pistonsweigh360grams.

Adding an extra Keyway Groove to the 88mm Crankshat Let: 88mm Crankshat, Right: 89.6mm Crankshat

Boththesecranks,originallyroma2 literEuropeanDiesel,needmodications beoretheycanbeinstalledintheM42or M44Block.Shownletistheearlierversion,an88strokewith8counterweights whichiseasiertoadaptortheengine. Thelatercrankontherighthasan89.6 mmstrokewith4smallercounterweights. Becausethiscrankrunswithacounterbalancesystem,itisarmoredicultto adaptin.Theneededadaptorsareshown abovewiththecranks. Page 

The 88 stroke crank must have the nose turned down and a second keyway added to secure the chain sprocket and ront harmonic balancer hub. Close-ups are shown o themachiningprocess(above) andtheendresulttothelet. Crankshat Nose adapted to accept the Stock Crank Sprocket


M42 M44 Rods Metric Mechanic Rod Line-Up: the usual prospects!

Far let at 140mm long is theM44540gramrod.Next, an 140mm long M42 Rod thatweighs610grams.These are used in our 2000 Sport Engines.ThethirdrodisMM’s Ultralite“I”Beamrod,138mm longandonly475grams,used in our 2100 Rally engines. Fourthonthearrightisthe MM“H”Beamrod.It’salso 138mm long, weighing in at 525grams.Thisrodsisgenerallyusedinboostedengines. From Let: M44 Stock Rod, M42 Stock Rod, MM Ultralite “I” Beam and MM “H” Beam Rods

OurMMRallyrodsshowntothelet, aremuchlighterandtwiceasstrongas thestockproductionrods.Forgedrom 4340 chrome moly steel, makes them superiorinstrengthtobilletrods.Then theyareullyCNCmachinedtosculpturedownexcessweightandnallyshot peenedtoimprovesuracestrength.They arecappedowith3/8”ARPbolts.The small ends o each rod are coupled to the piston with a 21mm lightweight 80 gramwristpin.Bycomparison,thestock pistonpinweighs105grams.

Let: MM Ultralite “I” Beam Rod Right: MM “H” Beam Rod

Wrist Pins: Let 21mm, 105 gram Turbo, Middle 21mm 80 gram Rally, Right 22mm tapered wall 89 gram Sport

Benefts o Reducing the Reciprocating Mass Reducing reciprocating mass weight (piston&rodassembly)hasaargreater eectonaccelerationthanreducingthe rotational mass. Lightening a rotational mass component such as a fywheel, comesintoplayonlyunderacceleration butthereciprocatingmassisconstantly accelerating and decelerating. At 7000 rpm,thepistonandrodassemblyisgoing rom0mphto100mphandbackto0 mph-14,000timesinoneminutesince thepistonchangesdirectiontwiceatthe top and bottom during onerevolution. The jerking motion against the piston goesto1500G-Force.Usingalightweight reciprocatingmassassemblywillnotonly makeanenginespoolupquicker but it willgreatlyincreaseitsreliability.


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M42, M44 Oiling System Ample Oiling - the “Lie Blood” o a Healthy Perormance Engine

Oiling Problems Inherent in the stock M42 M44 Engines Oil Pressure Loss rom Failed Pan Gasket Theoilpumpisdrivenotherontothecrankshatandsitsintheronthousing.Theoilpanseals betweentheoilpumpandtheoilpumppick-up. Oilpanboltsarehiddeninsidetheoilpan.Sometimesthey’llcomelooseandalldownintotheoil pan.Whenthishappens,airgetsdrawninbetween thepumpandthepick-upromthelooseoilpan gasket(loosenedbythedislodgedbolts).Intheend theengineloosesit’soilpressureandtheoilpump won’tprimeup.

Thrust Bearing Failures Stock M42M44enginesonly have athrustsuraceonthetopMainBearing.Becauseothislimitedthrustarea,thethrustsuracecanwearout.

Worn out stock thrust bearing rom an M42 engine.

360° Main Bearing Oiling System: double thrust bearings.

MM Solution or Thrust Bearing Failure

We use main bearings with a thrust surace on boththetopandthebottom.

High RPM Oil Starvation Thestockmainbearingshaveabouta200°oiling grooveandoilisshutototherodbearingsrom MM Solution or Failed Pan Gasket bottomdeadcentertotopdeadcenter.Thiscauses Ouroilpangasketisreinorcedbyasiliconseal- oilstarvationathighrpm. ingbeaddirectlyonthiscriticalpick-uppoint.We MM Solution or High RPM Oil Starvation alsouseBlueLoctiteontheinternaloilpanboltsto Thesebearingsalsoeaturea360°oilinggrooveso preventthemromworkinglooseintheuture. therodbearinghasaconstantsupplyooil.

Usingamilling machineand customkeyway cutter.140”wide, wemachinein thenewlocktang groovetoaccept the360°oiling mainbearings. The bottom main bearing cap has two narrow lock tang grooves. The 360° Main Bearings that weuse,haveasinglelocktangthatis3.5mmwide. Thereorethestockbearingcapmustbemodiedto acceptthewiderlocktang.

Page 0

360° Oiling Main Bearings Installed.


Oiling System

Timing Chain

continued & the

Rod Bearings, Timing Chain & Windage Tray Scrapper System

Upgrading the Rod Bearings Currently, we use one o three rod bearings in ourM42/M44engines.Thestockaluminumaced bearingontherightworkswellinourSportengines. Nextisaheavydutytri-metalrodbearingwitha thinBabbitacing,copperunderlayandasteelbacking.ThisbearingisusedinourdailydriverRally engines.Shown right isthesamebearing but with aTefoncoatedacewhichincreasesbearinglieby three times under race conditions. These bearings areusedinourDriver’sSchoolMMRallyengines. Remember,uponrequesttheseTefonCoatedbearingscanbeusedinanyMetricMechanicengine!

E30 2100 Rally Windage Tray/Scrapper Awindagetray’sunctionistoseparatethecrankshatromtheoilinthesumpandthebuiltinscrapperisusedtopullooilsprayromthecrankshat anddeposititbackintotheoilsump.Thewindage tray also keeps the oil level in the pan calm and insures that the pick-up remains submerged. Furthermore,byreducingoildragonthecrankshat, theenginegainsa couple moreHP.Our Windage Tray/ScrapperBarSystemisanadditional$350and availableonlytothosewhopurchaseanenginerom us.Wecannotsellitasaseparateunitbecauseit requirescustommachiningandtting.Thewindage trayshownbelowdoesnotapplytotheE36M42/ M44 because they come stock with oil pans that haveamagnesiumwindagetraybuiltrightin.

Let to Right: Stock Aluminum Faced Bearing, Heavy Duty Tri Metal, Heavy Duty Tri-Metal Bearing with Tefon Coated Face

Single Row Timing Chain Conversion Foryearswehaveusedsinglerowtimingchains ontheM10,M30singleoverheadcamengines.They haveproventobeextremelyreliabletothepoint where we trust them more than the Double row chain.Yesthedualrowisphysicallystrongerbutdue tothecentriugalorceothespinningchain,the sheermassothedoublerowchaincancausethe chainlinkstostretchandwearoutandthechain’s whippingactioncanalsocauseexcessivewearonthe guide and tensioner rail. Converting to the single rowchainreducestherotatingmassothechainand sprocketbyabout2lbsandto-datewehavenever hadachainailureromthismodication. Adds$200tothecostoanyM42M44engine. Frontal View o reversed Block showing Windage Tray on underside. Machined single row sprocket set or use in our M42 M44 engines. Let is the MM Single Row Sprocket and Chain Right is a Stock Double Row Sprocket and Chain Copyright© November 2006 by Metric Mechanic Inc™ 505 East Main, Richland, MO 6555 6 PH: 573-765-1269 FAX: 573-765-4216, Email:[email protected], www.metricmechanic.com

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MM Rally Cam & Valve Train Components Upgraded Valve Train Components

Metric Mechanic

Rally Cams for the M42 Engine

.005

272° Intake

258° Exhaust

272°

258°

.010

260°

246°

.015

254°

242°

.020

252°

238°

.050

234°

224°

.100

212°

202°

.200

174°

166°

.300

132°

124°

.400

76°

64°

Lift

.448” 11.4mm

.439” 11.15mm

Metric Mechanic - M42 Rally Cam Timing Map Intake Cam - 270° Dur. / 11.4mm Lift at .005” - Open 20° BTDC - Close 70° ABDC Exhaust Cam - 250° Dur. / 11.15mm Lift at .005“ - Open 55° BBDC - Close 14° ATDC Valve Opening During Overlap ...................Intake .025” (.63 mm) .................................................................................Exhaust .020“ (.51 mm)

TDC Intake Opens at 20° BTDC

Intake Lift Off Seat

Exhaust Cam - 240

.032” ATDC

Intake Cam - 264 I n t a

k e

a

h x E

s t

u

Exhaust Lift Off Seat

Exhaust Closes at 14° ATDC

.028” ATDC

Exhaust Opens at 55° BBDC

Rally Cam Description

Intake Closes at 70° ABDC

OurRallycamspullstrongalltheway totheir 7700 redline in our 2100 Rally Valve Adjustment Intake .011” ± .101 Engine. These cams are rather top end Exhaust .013” ± .001 happybutwillpullstrong rom4300rpms whencombinedwithourpulsechamber intakemaniold.Thesecamsneedtobe usedwithour“BeeHive”valvesprings andlightweight6mmretainers.Thevalve trainshouldbelightenedupwith6mm valves.MM’sheavydutyhydraulicliter bucketsworkwellwithourRallycamsor high RPM maintenance ree operation. For extremehigh RPM running, switch overtoourMMMechanicalLiterBucket System.ShimpadsareromanE46S54 engine.Valveadjustmentis.004”to.005” Bee Hive Spring, Retainer whenusedwithahydrauliccam. & Stock Spring Perch

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BDC

TDC BDC BTDC ATDC BBDC ABDC

Top Dead Center Bottom Dead Center Before Top Dead Center After Top Dead Center Before Bottom Dead Center After Bottom Dead Center

Let: MM Heavy Duty Hydraulic Liter Right: MM Mechanical Liter with shim pad


Lightening the M42 Valve Train Reduced by Over 50 Grams per Valve Assembly!


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M42 E30 Pulse Chamber Intake Manifold Increasing Bottom End and Mid Range

M42/E30 Pulse Chamber Intake Manifold Our MM Pulse Chamber Intake Maniold greatly increases bottom end and midrangetorqueintheM42 engine. When looking closely at the base o the“C”runnersonan M42 E30, capped o tubeextensionsarevisible.Wecallthesepulse chambers. How Does the Maniold Work?

Aterthe intake mixture (uel and air mixture) enters a cylinder, the intake valve slams shut.Inthestockmaniold, the intake mixture starts to recoil o Intake Maniold the back o the intake PulseonChamber a 2100 Rally Engine valveandback-fowsup theintakerunnertotheplenum.Butwithapulse chambermaniold,the intakemixturegoesstraight backintothepulsechamberbecausethatisthepath oleastresistance.Nextthemixturerecoilsothe back o the capped-o tube (the pulse chamber) and heads or the back o the intake valve ready to enter the engine when the intake valve opens. Sincetheintakemixtureisreadytogointothecylinder,thecylinderllingisincreasedandtheengine makesmorepower.FrompastDynotesting,wecan claima15%increaseinmidrangetorquewiththis maniold. Side View o the Pulse Chamber Intake Runner

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M42/M44 Lightweight Flywheel & Clutch Assembly Best Perormance Modifcation or the Money

Let to Right: Lightweight Flywheel & Bolts, 228mm Disc with Sprung Hub, 228mm Pressure Plate and Throw Out Bearing

Description From the actory, M42/M44 engines use large heavydualmassfywheelswith215mmclutchassemblies.Inproportiontotheenginedisplacement,we think this fywheel sets the record or being the heaviestBMWfywheelscalinginatamassive28.25 lbs.Wereplaceitwithasinglemassfywheelweighing11to11.5lbs.andupgradetoa228mmclutch assembly.

How a Lightened Flywheel Works

Whileanenginerevs,thefywheelcreatesaparasiticdragontheengine’sabilitytoaccelerate.The aster the fywheel is accelerated, the greater the powerlosstotheengine. Forexample,apairotestsona3700,rstwith thestock23lb.andsecondwiththefywheellighteneddownto12.5lbs.revealedanimpressivegain. The Signifcance When accelerated at 1500 RPMs per second, the Thestock215mmclutchcantakeuptoabout155 enginepickedup17HPwiththelightenedfywheel. t.lbs.otorque.The228clutchassemblyweuse Considerthis:1500RPMspersecondisequivalent canhandleuptoabout230t.lbs.otorque.Going to a 1st gear acceleration. Here’s another way to toa228clutchwillvirtuallyeliminateanyneedor lookatit:everypoundremovedromthefywheel, a clutch replacement. This amount o “overkill” iscomparabletotaking15lbs.othebodyweight. reducestheprobabilityoeverhavingtoreplacethe Summary clutch.Forthemoney,alightenedfywheelwith228 Installing a lightened fywheel does not generate clutchassemblyisthebestperormancemodica- moreHPinanengine.It’smorelikethereduction tionyoucandotoanM42orM44. oaloss. Copyright© November 2006 by Metric Mechanic Inc™ 505 East Main, Richland, MO 6555 6 PH: 573-765-1269 FAX: 573-765-4216, Email:[email protected], www.metricmechanic.com

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2000 Sport M42 Engine -

Spec Sheet For the Enthusiastic Street Driver

MM 2000 Sport Engine Displacement ........................1925cc BorexStroke........................87mmx81mm CompressionRatio..............11.0:1 Horsepower...........................170@6500 Torque ....................................145@4500 Redline................................... 7000rpm

Block Components Crankshat............................. Stock81mmstrokeorgedsteelwith8counterweights,29.5lbs. Rods........................................ StockM42/1.8rod,595grams Optional: Stock M44/1.9 rod, 540 grams Pistons MM87mm.................... LightweightForgedAlusilPistonventedskirts 11.0:1 Compression Ratio/ 310 grams StockCastPiston..........10.0:1CompressionRatio/360grams Rings....................................... 1.5mmMolyTop,1.5mm2ndand3.0mm 3 piece Oil Ring (low radial tension design) PistonPin..............................22mmtaperedwall,89grams Stock............................... 22mm/105grams

Oiling Block Modifcations MainBearings....................... Stockmainbearingswith200°oilinggrooveand360°thrust bearingsurace RodBearings......................... Stockaluminumacebearings Option:Tri-metalheavydutyTefoncoatedbearings Windage Tray(E30only) ........ Optional:Awindagetray/scraperassembleisinstalledtopeel slingingoilothecrankandsendittotheoilpick-up.

Head Assembly HeadFlow............................. 6%overstock HeadBolts............................. MMsocketheadbolts100mmlongtorquedto64ft.lbs.reusable ..........................................Stocktorquetoyieldtorxheadbolts90mmlong-nonreusable Cams.......................................MMSportCams Intake:262°Duration/11.15mmLit Exhaust: 228° Duration / 9.0 Lit HydraulicLiter.................... MMheavydutyhydraulicliterwithnitratedcrown Valves......................................33.0mmintakeand30.5mmexhaustwithSuraceTurbulence and7mmstems ..........................................Optional:lighterweight33.0mmintakeand30.5mmexhaust withSuraceTurbulenceand6mmstems ValveSpring...........................MM“BeeHive”springwithlight7mmretainer Optional:MM“BeeHive”springwithlight6mmretainer(25 gramslighterthanthestockdualspringwith7mmretainer) ValveGuide...........................MM7mmmanganesebronze ..........................................Option:MMshortened6mmmanganesebronze

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2000 Sport M44

/M42 Engine -

OBDII

Spec Sheet

For the Enthusiastic Street Driver

MM 2000 Sport Engine Displacement ........................1973cc BorexStroke ........................87mmx83mm CompressionRatio..............11.0:1 Horsepower...........................175@6500 Torque....................................150@4500 Redline................................... 7000rpm

Block Components Crankshat............................. Stock83mmstrokecastwith4counterweights,28.5lbs. .......................................... withOBDII/60toothtimingwheel Rods........................................ StockM44/1.9rod,540grams Pistons MM87mm.................... LightweightForgedAlusilPistonventedskirts 11.0:1 Compression Ratio/ 310 grams StockCastPiston..........10.0:1CompressionRatio/360grams Rings.......................................1.5mmMolyTop,1.5mm2ndand3.0mm 3 piece Oil Ring (low radial tension design) PistonPin..............................22mmtaperedwall,89grams Stock............................... 22mm/105grams

Oiling Block Modifcations MainBearings....................... Stockmainbearingswith200°oilinggrooveand360°thrust bearingsurace RodBearings......................... Stockaluminumacebearings Option:Tri-metalheavydutyTefoncoatedbearings Windage Tray(E36only) ........ Stockaluminumwindagetrayinoilpan

Head Assembly HeadFlow............................. 6%overstock HeadBolts............................. MMsocketheadbolts100mmlongtorquedto64ft.lbs.reusable ..........................................Stocktorquetoyieldtorxheadbolts90mmlong-nonreusable Cams.......................................MMSportCams Intake:262°Duration/11.15mmLit Exhaust: 228° Duration / 9.0 Lit HydraulicLiter.................... MMheavydutyhydraulicliterwithnitratedcrown Valves......................................33.0mmintakeand30.5mmexhaustwithSuraceTurbulence and6mmstems ValveSpring...........................MM“BeeHive”springwithlight6mmretainer ValveGuide...........................MM6mmshortenedmanganesebronze


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2100 Rally M42 Engine -

Spec Sheet

For Hard Street and Driver School Use

MM 2100 Rally Engine Displacement ........................2091cc Bore......................................... 87mmxstoke88mm CompressionRatio..............11.5:1 Horsepower...........................205@7350 Torque ....................................165@5150 Redline................................... 7700rpm Acceleration...........................0-60-6.5sec. 1/4 mile - 14.5 sec. / 98 mph

Block Components Crankshat............................. 88mmstrokeorgedsteelcrankwith8counterweights,29.5lbs. stock 81mm stoke orged steel Rods........................................ MM138Ultralite“I”BeamRod,480grams or MM 138 mm “H” Beam Rod, 540 grams ‘95 & newer Pistons MM87mm.................... LightweightForgedAlusilPistonventedskirts 11.5 Compression Ratio/ 310 grams StockCastPiston..........10.0CompressionRatio/360grams Rings....................................... 1.5mmMolyTop,1.5mm2ndand3.0mm 3 piece Oil Ring (low radial tension design) PistonPin..............................21mm/80grams Stock............................... 22mm/105grams

Oiling Block Modifcations AntiDrainBackValve.........Valveaddedorhydraulicliterbucketstokeepthelitersrom drainingdown MainBearings....................... 360°oilgroovetoinsureaconstantfowooiltotherod bearings.Stockmainbearingshaveonlya200°oilinggroove. thispreventsoilromeedingtotherodbearingsrombottom totopdeadcenter.Alsohavea360°thrustbearing-thestock thrustbearingis180° RodBearings......................... Tri-metalheavydutyTefoncoatedbearings WindageTray....................... Optional:Awindagetray/scraperassembleisinstalledtopeel slingingoilothecrankandsendittotheoilpick-up.

Head Assembly HeadFlow............................. 6%overstock HeadBolts............................. MMsocketheadbolts100mmlongtorquedto64ft.lbs.reusable ..........................................Stocktorquetoyieldtorxheadbolts90mmlong-nonreusable Cams.......................................MMRallyCams Intake:272°Duration/11.4mmLit Exhaust: 250° Duration / 10.9 Lit HydraulicLiter.................... LighterLateModelM50tu35mmLiter ValveSpring...........................MM“BeeHive”springwithlight6mmretainer(25grams lighterthanthestockdualspringwith7mmretainer) Valves......................................SuraceTurbulencewith6mmstems, Stock valves have 7mm stems ValveGuide...........................Shorter6mmmanganesebronze Stock are 7mm brass

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MM Forced Induction M42/M44 Engines Considerations in choosing Forced Induction

Forthosewanting200HPormoreromanM42 MM 1900, 2000 and 2100 Forced Induction orM44engine,aForcedInductionEngineisthe Engines answer. ThisM42/M44Seriesisspecicallydesignedand engineeredtorunsuccessullyunderboost.Theyare Considerations Beore Making the Move to not merely decompressed stock engines which are Forced Induction limited to about 7 lbs.(.5 bars) o boost and are A2100Rallyenginewilldothe1/4milein14.5sec shortlived.Aboostedenginelivesahardtoughlie at98.5mph.ThisisasastasanE36M3.Equipped andneedstobebuiltstronganddurablesoitcan witha PulseChamberIntake Maniold, it’spower takethedemandsovertime.Longevitymustbea bandisrom4300to7300RPM.Theenginepulls majordesigngoalalongwithpower. likeitsrunningon6cylindersandgets30mpgon the highway. Forced Induction is more complex The Reciprocating Mass o Metric Mechanic’s withaboostapparatusandextraplumbing.Thecost Forced Induction Engines oaForcedInductionSystem,onceit’sall plumbedupandtuned,canbeasmuchas theengineitsel. Two Camps

OK!You reallywanttodoit?Then the rstdecisionistodeterminewhichcamp youbelongwith-theSuperchargecrowdor theTurbopeople.Bothsystemshavetheir meritsanddrawbacks. Bower Bands

A boost device such as the Downing Atlantic Supercharger, will be strong at makingbottomendandmidrangetorque but tends to all o on the top end. In comparison,aTurbo-Chargedengineeels ratherfatdownlowbutmuchstrongerin themid-rangeandtopend.Now,thepowerbando MM Forced Induction Piston, Pin and Rod Assembly eithersystemcanbemovedupordowndepending onhowthesystemissizedtotheengine. Forced Induction Piston Comparisons

Since the Supercharger is driven o the crankshat,it’spoweroutputisdictatedbyRPMwhereas aTurboisdrivenbytheengine’sexhaustoutputand isconsequentlydictatedbyengineload.Becausethe Turboisdrivenbyarelatively“ree”powersource (exhaust),itismuchmoreecientandsinceitrelies onengineload,ithasmorepowerpotentialthana Supercharger. So,iitisbottom-endandmid-rangetorqueyou are ater, choose a Supercharger or small Turbo System,butiyouareinterestedinasizeablepower increase,nothingbeatsaTurbocharger.

The piston, more than any other component, receives the most abuse in a orced induction engine.Heatgeneratedromboostandparticularly detonation can be so intense it can literally melt thepiston.Becauseothis,ourorgedalusilpiston hasa.080”(2mm)thickercrownthanournormally aspiratedpistons.Thetopothepistonisintentionallymadefat with novalvepocketsbecausevalve pockets create a thin eyebrow at the edge o the pistonandthisthinedgeistheveryrstplacethe pistonstartsitsmeltdown.Also,theuppercompressionringgrooveismovedurtherdownthepiston toprotectthetopcompressionringromheat.Our orcedinductionpistonweighs380grams.


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MM Forced Induction M42/M44 Engines Cooling the Forced Induction Piston

Piston Pin

Weuseathickwall21mmwristpinweighing105 grams. Rod

Therodisan“H”beamdesignorgedandCNC machinedouto4340ChromeMolySteel.Atthe bigend,wemachine4oilinggrooves,(seeclose-up onpage19)throughwhichoilsquirtstowardsthe bottomothepistontocooltheskirt.Threedierentrodsareusedintheseengines;the138mmrod or1900FIengine,the137mmrodora2000FI engineanda134.5mmrodora2100FIengine.

charged out through these 4 oil squirter grooves onto the bottom side o the piston. Oil then splashesthroughthehorizontalslitsmachinedinto thepistonjustundertheoilringgroove.Theseslits notonlygreatlyhelpreducepistonexpansionbut theyalsogivetheoilapathwaytowardstheupper portionothepistonskirt,lubricatingitromthe cylinderwall.Evenwithatightttingpiston(.003”), theskirtstayswelllubricatedwhichgreatlyincreases the skirt lie and reduces the likelihood o a collapsedorseizedpistonskirt.Thelubricatingmethod describedabovedoesnotroboilpressureromthe enginelikemoreconventionalblocksquirters.

Main Bearings with 360° Oiling Groove

Double Thrust Main Bearing Set

Main Bearings

Thestockmainbearingshaveabouta200°oiling grooveandoilisshut ototherodbearingrom Oil Cooling the MM Forced Induction Piston, Pin and Rod Assembly bottomdeadcentertotopdeadcenter.Thiscauses oilstarvationtotherodbearings.Themainbearings weusehavea360°oilinggroovesotherodbearing Internal Cooling o the Forced Induction Piston hasaconstantsupplyooil.Wealsouseadouble Thesameouroilinggrooves alsohelpcoolthe thrustsuracemainbearing.Thestockmainbearpiston internally. Oil coming o the rod bearing ingsonlyuseasinglethrustsuracewhichtendsto iscollectedintherod’ssidechamerandthendis- wearout.

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MM Forced Induction M42/M44 Engines More Parts Specialized or the Forced Induction Engine

Rod Bearings

Let to Right: Stock , Tri-Metal & Tefon Coated Rod Bearings

The stock rod journal is only 45mm in diameter.Thisrathersmalljournaldiameterseesaloto loadunderboost.Totakethishigherload,weusea TefoncoatedTri-Metalrodbearingthatcandeliver threetimesthelieoastockrodbearing. MM Cylinder Head

Let: Forced Induction Multi-layered Head Gasket Right is Normally Aspirated Composite Head Gasket

OurM42/M44headsfow6%overstock.These Multi-Layered Stainless Steel Head Gasket headshaveourpatentedSuraceTurbulenceconcenWeuseathreelayeredstainlesssteelheadgasket. tricgroovesmachinedintothebacksideotheintake Thetopandbottomlayersareembossedandcoated valveandtheheadsoboth with Viton or good sealing properties. A thicker theintakeandexhaustvalves. innerstainlesssteelcoreisusedorhighstrength. ThishelpstoreducedetonaThisgasketdoesnotrequireretorquingandcanbe tion in a boosted engine. It reusedinotdamaged. alsohelpspreventheadcracking,increasesuelmileageand MM Head Bolts helpsreduceemissions. Thesocketheadboltswebuildwithare100mm long(10mmlongerthanstock)ordeepanchorCams and Valve Train Thestockcamsareusedonthesmaller1900and ingpowerintheblock.Thisspreadstheloadmore 2000 Forced Induction Engines. The 2100 Forced evenlyover the cylinder wall and reduces cylinder InductionEnginesusea258°duration/11.15mm walldistortionevenundergreaterheadtorque(68t. litcamonboththeintakeandexhaustcam.MM lbs.)Stockheadboltshitabout59t.lbs.whenthey “BeHive”valvespringsandlighterretainersareused areangletorqued. alongwithMM35mmheavydutyhydraulicliter buckets.

Main Bearings with 360° Oiling Groove Copyright© November 2006 by Metric Mechanic Inc™ 505 East Main, Richland, MO 6555 6 PH: 573-765-1269 FAX: 573-765-4216, Email:[email protected], www.metricmechanic.com

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1900 M42 Forced Induction -

Spec Sheet

For Boosting ... Supercharging or Turbocharging

MM 1900 M42 FI Engine Introduction

This engine is designed and engineered to run 5. RINGS underboostromtheorcedinductionoaTurbo Topis1.5mmMoly,secondis1.5mmandthe4mm Charger, Supercharger or Blower. The head bolts, oilringisahighradialtensiondesignwith3pieces. headgasket,pistons,wristpins,rings,rodsandrod bearingsareallstrongerpartsspecicallydeveloped 6. PISTON PINS torununderboost.BecausethisisalargerdisplaceThe21mmpinweuseonboostedenginesweighs105 mentenginewithbetterheadfowthanstock, the gramswhileonanormallyaspiratedengineitweighs power output will be much higher than a stock 80grams. engineatthesameboostlevel.

1. DISPLACEMENT 1881cc(86mmborex81mmstroke)

2. CRANKSHAFT Thisengineusesastock1.8orgedsteelcrankshat with8counterweightsandan81stroke.

3. ROD These“H”beamrodsareorgedrom4340Chrome Moly steel or strength, ully CNC machined or lightness, 138mm long and weigh only 525 grams. The“H”BeamRodsaremodiedwith4oilgrooves machinedintothebigendthatallowoilsquirtsinto thebottomsideothepistontohelpcoolito.

4. PISTON

7. MAIN BEARINGS Weusea360°oilgrooveonthemainbearings.The stockmainbearingstopseedingoiltotherodbearingrombottomdeadcentertotopdeadcenter,so, athighrpmstherodbearingsbecomestarvedoroil. Thiscircularoilgroovekeepstherodbearingswell lubricated.

8. ROD BEARINGS We use tri-metal rod bearing with a tefon coated babbitacing,acopperunderlayandasteelbacking. Inourexperience,theyare3timesmorereliablethan stock.

10. HEAD CurrentlyourM42/M44headsfow6%overstock. We install our 6mm Suraced Turbulenced valves whichhelpreducedetonation,increaseueleconomy andminimizecrackingandthenpairthemwithmanganesebronzevalveguidesorgreatlyincreaselie. MM“BeeHive”valvespringsandlightweightretainers reduce valvetrain weight. Valvesare capped o withMM35mmheavydutyhydraulicliters.

Weusean86mmForgedAlusilPistondesignedspecically or boosted engines with 8.6 compression ratiothathasafattopandnovalvepocketing.The crownthicknessat.080is2mmthickerthanournormallyaspiratedpiston. To prevent heatdamage to thetopcompressionring,it’smoveddownloweron thepiston.Mostboostedenginesrunalotocylinderwallclearance(usually.005”to.006”)tokeep thepistonromstickinginthebore.Weuseaspe- 10. HEAD GASKET & HEAD BOLTS Our choice is a Cometic multi layer metric head cial13%highsiliconcontentpistontolowerpiston gasket withstronger 10mm socket-headboltsthat expansionandreducescung.Ourpistonsalsohave are100mmlongwhichis10mmlongerthanstock. ahorizontalslitjustbelowtheoilringtoprevent the heat that’s coming o thepiston crown rom transerringdirectlytotheskirtothepiston.This 11. CAMMING Stockcams-228°durationwith9mmlit. slithelpsreducetheexpansionrateattheskirt4-7% morethanacastpiston.Mostorgedpistonsexpand 35-50%morethanastockcastpiston.Werun.003” 12. HORSEPOWER OUTPUT 200-250HP pistontocylinderwallclearance. Page 



Spec Sheet


MM 2000 M44 FI Engine Introduction

morethanacastpiston.Mostorgedpistonsexpand 35-50%morethanastockcastpiston.Werun.003” pistontocylinderwallclearance.

This engine is intended or OBDII M44/1.9 enginesrom1996onthatwillberununderboost 5. RINGS Topis1.5mmMoly,secondis1.5mmandthe4mm rom the orced induction o a Turbo Charger, oilringisahighradialtensiondesignwith3pieces. SuperchargerorBlower.Theheadbolts,headgasket, pistons,wristpins,rings,rodsandrodbearingsare allstrongerpartsspecicallydevelopedtorununder 6. PISTON PINS boost.Becausethisisalargerdisplacementengine The21mmpinweuseonboostedenginesweighs withbetterheadfowthanstock,thepoweroutput 105gramswhileonanormallyaspiratedengineit willbemuchhigherthanastockengineatthesame weighs80grams. boostlevel.


2. CRANKSHAFT Thisengineusesastock1.9castironcrankshatwith 4counterweightsandan83stroke.Thetimingwheel is mounted on the 4th counterweight or OBDII timingreerence.

3. ROD These“H”beamrodsareorgedrom4340Chrome Moly steel or strength, ully CNC machined or lightness, 137mm long andweighonly 520 grams. The“H”BeamRodsaremodiedwith4oilgrooves machinedintothebigendthatallowoilsquirtsinto thebottomsideothepistontohelpcoolito.

4. PISTON


8. ROD BEARINGS We use tri-metal rod bearing with a tefon coated babbitacing,acopperunderlayandasteelbacking. Inourexperience,theyare3timesmorereliablethan stock.

9. HEAD CurrentlyourM42/M44headsfow6%overstock. Weuse6mmSuracedTurbulencedvalveswhichhelp reducedetonation,increaseueleconomyandminimizecrackingandthenpairthemwithmanganese bronze valve guides or greatly increase lie. MM “Bee Hive” valve springs and lightweight retainers reducevalvetrainweight.Valvesarecappedowith MM35mmheavydutyhydraulicliters.

Weusean86mmForgedAlusilPistondesignedspecically or boosted engines with 8.6 compression ratiothathasafattopandnovalvepocketing.The crownthicknessat.080is2mmthickerthanour normallyaspiratedpiston.Topreventheatdamage tothetopcompressionring,itsmoveddownlower 10. HEAD GASKET & HEAD BOLTS onthepiston.MostboostedenginesrunalotocylOur choice is a Cometic multi layer metric head inderwallclearance(usually.005”to.006”)tokeep gasket withstronger10 mm socket-headboltsthat thepistonromstickinginthebore.Weuseaspeare100mmlongwhichis10mmlongerthanstock. cial13%highsiliconcontentpistontolowerpiston expansionandreducescung.Ourpistonsalsohave 11. CAMMING ahorizontalslitjustbelowtheoilringtoprevent Stockcams-228°durationwith9mmlit. theheat that’scoming o the piston crown rom transerringdirectlytotheskirtothepiston.This 12. HORSEPOWER OUTPUT slithelpsreducetheexpansionrateattheskirt4-7% 200-250HP Copyright© November 2006 by Metric Mechanic Inc™ 505 East Main, Richland, MO 6555 6 PH: 573-765-1269 FAX: 573-765-4216, Email:[email protected], www.metricmechanic.com

Page 


Spec Sheet


MM 2100 M42 Turbo Engine Introduction

For “boost junkies” seeking a 300 HP thrill, thisorcedinductionengineistheanswersinceits designedandengineeredtorununderboostroma Turbo Charger,Supercharger or Blower. The head bolts, head gasket, pistons, wrist pins, rings, rods and rod bearings are all stronger parts specically developedtorun underboost.Because this isour largest displacement engine with better head fow and hotter cams (dierentiating itrom ourother boosted engines) the power output will be much higherthanourotherboostedengines.


2. CRANKSHAFT Weuseamodieddieselcrankwithan88mmstroke. Theboltthatretainstheharmonicbalanceradaptor is2mmlargerandwewouldneedthesupercharge drivepulltoadaptittotheengine. 

3. ROD Fortheboostedengineweusea134.5mmlong“H” BeamRodweighing500grams.The“H”BeamRods aremodiedwith4oilgroovesmachinedintothe bigend. Theseallow oiltosquirtintothebottom sideothepistontohelpcoolito.

4. PISTON

morethanacastpiston.Mostorgedpistonsexpand 35-50%morethanastockcastpiston.Werun.003” pistontocylinderwallclearance.

5. RINGS Topis1.5mmMoly,secondis1.5mmandthe4mm oilringisahighradialtensiondesignwith3pieces.

6. PISTON PINS The21mmpinweuseonboostedenginesweighs 105grams. 


8. ROD BEARINGS We use tri-metal rod bearing with a tefon coated babbitacing,acopperunderlayandasteelbacking. Inourexperience,theyare3timesmorereliablethan stock.

9. HEAD CurrentlyourM42/M44headsfow6%overstock. Weuse6mmSuracedTurbulencedvalveswhichhelp reducedetonation,increaseueleconomyandminimize crackingand then pair them with manganese bronze valve guides or greatly increase lie. MM “Bee Hive” valve springs and lightweight retainers reducevalvetrainweight.Valvesarecappedowith MM35mmheavydutyhydraulicliters.

Weusean86mmForgedAlusilPistondesignedspecically or boosted engines with 8.6 compression ratiothathasafattopandnovalvepocketing.The crownthicknessat.080is2mmthickerthanour normallyaspiratedpiston.Topreventheatdamage 10. HEAD GASKET & HEAD BOLTS tothetopcompressionring,itsmoveddownlower WeuseaCometicmultilayerMetricHeadGasket onthepiston.Mostboostedenginesrunalotocylandstronger10mmSocket-headBoltsthatare100 inderwallclearance(usually.005”to.006”)tokeep mmlongwhichis10mmlongerthanstock. thepistonromstickinginthebore.Weuseaspecial13%highsiliconcontentpistontolowerpiston 11. CAMMING expansionandreducescung.Ourpistonsalsohave Weusea258°duration/11.15mmlitcamonboth ahorizontalslitjustbelowtheoilringtoprevent intakeandexhaust. the heat that’s coming o thepiston crown rom transerringdirectlytotheskirtothepiston.This 12. HORSEPOWER OUTPUT slithelpsreducetheexpansionrateattheskirt4-7% 250-350HP Page 


M42/M44 Prices Prices Subject to Change

M42 & M44 Engine Prices

Heads

M42: E30 (90-91), E36 (92-95), Z3 ‘95 M44: E36/5 318ti (96-98) E36 318i (96-98) Z3 96-98

Core Deposit $ SportM42......... 160HP........ 6,495... 800

2000 2100 SportM44......... 170HP........$6,795 .. 1200 2100 RallyM42.......... 205HP........$8,495... 800 FORCED IN DUCTION

1900 FIM42............. 225HP........$6,995... 800 2000 FIM44 ............. 225HP........$7,295 .. 1200 2100 FIM42 ............. 300HP........$8,995... 800 Pistons & Rings MMSport87mmForgedAlusilPiston M421.0:1CR.. $780 MMSport87mmForgedAlusilPiston M441.0:1CR.. $780 MMSport87mmForgedAlusilPiston M421.5:1CR.. $780 78mmMolyRings................................................... $120

Rods & Bearings

Include: 6% Flow Increase, Surface Turbulence Valves, Manganese Valve Guides, MM “Bee HIve” Valve Springs & Lightweight Retainers Core Deposit $ MMM42/M44Head................... 1,495....... 600 Components

MM35mmHydraulicLiters...... $30Each... $400Set MM35mmMechanicalLiters.... $40Each... $600Set ShimPads...................................................... $5Each

MM“BeeHive”ValveSpring andRetainer.......................... $20Each... $300Set ManganeseBronzeValveGuide.. $12Each... $175Set MMSocketHeadBolt (100MM)... $7.50Each......$70Set MultilayerStainlessSteelHeadGasket For Forced Induction Engines ......... $7.50Each......$70Set Bolt-Ons Core Deposit MMLightenedFlywheel 11lbs. $ &228mmClutchAssembly.................. 755 .. 200

Rods (StockDualMassRingGearorFlywheelrequiredorcore) MMRally138mm“Ultralite”“I”BeamRod(475 g)........ $780 PulseChamberIntakeManiold(E30).... $995 .. 250 MMRally138mm“H”BeamRod(520 g) ...................... $700 MMForcedInduction“H”BeamRodswith4SquirterGrooves 134.5mm, 137mm or 138mm ...........................................$780 Rod Bearings SportAluminumFaceBearings.................... $60perSet Rally,ForcedInduction,Race: TefonCoatedTri-Metal.............................. $140perSet Main Bearings Mainswith360°Thrust&OilingGroove: Requires modifying lock tangs on the main bearing caps........ $120perSet

Crankshaft M42-88mmForgedSteelCrankKit: For 2100 Rally or 2100 Forced Induction ................................... $1250

Cams

Core Deposit $780.. 250

MMSportIntakeCam258°Duration/11.15mmLit..... MMRallyCams: Intake272°Duration/11.4mmLit Exhaust258°Duration/11.15mmLit......................... $900Pair 250 MMTurboCams: IntakeandExhaust272°Duration/11.4mmLit..... $900Pair 250


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Metric Mechanic m42 and m44 Engine Booklet

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