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Home > My Defender > M57 swap into the Red Baron

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shanecl Member Since: 20 Mar 2013 Location: Louth Posts: 494

M57 swap into the Red Baron Hi Folks Seeing as it has taken me 10 years to get to this point and have lost photos/cameras etc i never got to do a build thread. Its been completely rebuilt from the ground up, the only original part is the registration plate. It's also on disco 2 axles which i fitted a few years ago but I'm now doing a M57 swap and hopefully be of interest to others and help. I am using the last of the M57's the M57N2TÚ2 with the BMW ZF 6HP auto box which has come out of a 57 plate X5. Ends up the earlier engines are easier to fit due to the power steering pump being located at the top left of the engine rather then the bottom left leading to an interference of the power steering box. The 2 options are either fit the engine offset and higher or fit the P38 steering box outside the rails and have the engine sitting centered and lower between the rails. I'm going down this route and have sent Blackbird industries an email. I have also bought an E60 sump with dipstick and oil pickup as the X5 has a larger, webbed sump to take the front diff and this comes into contact with the front axle. you can cut this excess off with a grinder but my OCD wants everything to look like a factory fit hence the purchase. I also need to order some different coolant pipe connects as the X5 had a lot of radiators and rather then blanking off the ports I don't need I want to order the BMW parts that didn't have these extra connections, again in the vain of looking like a factory fit so trawling through bimmercat. Anyway onto the fun stuff, Click image to enlarge Sad day in the parish, Land Rover reconditioned 4.2 which I had machined to take GEMS engine management system and never used. auto boxis from a Discovery 2 V8 giving me the EH rather then Hydraulic Click image to enlarge The new power plant Click image to enlarge Click image to enlarge Click image to enlarge First job was to remove the V8 engine mounts and front radiator mounts as i am fitting a Puma radiator pack, I also have to fit elec fans as the TÚ2 has no viscous fan and again the older ones do. I had thought of seeing could I fit the older water pump and allowing me to use a viscous fan but I don't know will it fit or lead to problems down the road. Click image to enlarge Click image to enlarge no going back now Click image to enlarge and this is the reason for fitting the later model, all so i would have a nice gear selector inside Click image to enlarge

2nd Jan 2023 7:50pm

Linds Hanson Member Since: 16 Jan 2021 Location: Cornwall Posts: 484	Great work keep the progress coming
3rd Jan 2023 10:34am

shanecl Member Since: 20 Mar 2013 Location: Louth Posts: 494	Thanks Linds Great FB group where you and Dalton are helping me a lot
3rd Jan 2023 1:45pm

Mo Murphy Member Since: 01 Jun 2008 Location: Letchworth Garden City, Herts Posts: 2213	Looking forward to a video of your first drive 😁 Mo The Land Rover 90 - Many are called, few are chosen. 50 Shades of Pennine Grey
5th Jan 2023 10:18pm

TexasRover Member Since: 24 Nov 2022 Location: Paris Posts: 1005	I always wondered with these swaps, how do you successfully isolate the engine management system of the new engine from all the electrics integration that no doubt existed in the original setup. Is this a major software hack from some wizardry person or you just live with the error codes and the system design is robust enough to live with the lack of various inputs?
6th Jan 2023 8:15am

shanecl Member Since: 20 Mar 2013 Location: Louth Posts: 494	Mo Murphy wrote: Looking forward to a video of your first drive 😁 Mo Thanks Mo, I'm aiming for Paddys day for the parade lol Shane
6th Jan 2023 11:50am

shanecl Member Since: 20 Mar 2013 Location: Louth Posts: 494

TexasRover wrote: I always wondered with these swaps, how do you successfully isolate the engine management system of the new engine from all the electrics integration that no doubt existed in the original setup. Is this a major software hack from some wizardry person or you just live with the error codes and the system design is robust enough to live with the lack of various inputs? Luckily we have an awesome wizard on this forum but the name Martin and he works his magic on a black box I also got the ECU itself worked on by House of Torque Shane

6th Jan 2023 11:52am

JOW240725 Member Since: 04 May 2015 Location: Suffolk Posts: 7902	Great project! Hope it goes well. I'll look forward to seeing the results! James MY2012 110 2.2TDCi XS SW Orkney Grey - http://www.defender2.net/forum/topic43410.html MY1990 110 200TDi SW beautifully faded Portofino Red - https://www.defender2.net/forum/post743641.html#743641 MY1984 90 V8 Slate Grey - https://www.defender2.net/forum/post744557.html#744557 Instagram @suffolk_rovers
6th Jan 2023 10:10pm

shanecl Member Since: 20 Mar 2013 Location: Louth Posts: 494	Thanks James While i'm waiting on parts i decided to paint the auto box Click image to enlarge Click image to enlarge Had to keep the detail lol Click image to enlarge Click image to enlarge
9th Jan 2023 3:32pm

Linds Hanson Member Since: 16 Jan 2021 Location: Cornwall Posts: 484	Surprised it isnt Hemi orange
2nd Feb 2023 2:51pm

shanecl Member Since: 20 Mar 2013 Location: Louth Posts: 494	😜😜😜 lol I was thinking of other colours but then had a meeting with myself and said it was factory look i'm going lol Have more pictures to upload, waiting on parts and on the slow boat it seems.
3rd Feb 2023 2:40pm

shanecl Member Since: 20 Mar 2013 Location: Louth Posts: 494

Some updates, progress slow as constantly waiting on stuff. Bought the M57 E60 530 sump, while waiting i got it vapour blasted and a lick of paint Click image to enlarge ended up i got the wrong oil pickup so back onto Ebay and waiting again. proper one now fitted Click image to enlarge new sump gasket and sump back on Click image to enlarge I looked into stripping the injectors myself but was turning into a bigger job then I thought so I just put them into the ultrasonic cleaner, obviously not as good a job if stripped but I really got to start cutting back on the spending Click image to enlarge Click image to enlarge Click image to enlarge Bought all new rubber o-rings and copper washers Click image to enlarge Before i could re-install i had to clean the injector seats Click image to enlarge Click image to enlarge so new tool time Click image to enlarge Click image to enlarge oh yass very noice Click image to enlarge all ready for injectors and new rocker cover gasket Click image to enlarge Click image to enlarge Next job is to try and remove as much 'Glar' i'm told its called, the cruddy from the egr setup from the inlet manifold. I've tried oven cleane which done a decent job but was too runny, think i need a foaming one Click image to enlarge

20th Feb 2023 2:46pm

shanecl Member Since: 20 Mar 2013 Location: Louth Posts: 494

Engine in to tack in mounts and remove again to weld in fully I have fitted 330D PAS pump and aircon pump to give me more room to lower the engine as the X5 PAS pump was coming into contact with the chassis leg. I reckon I can keep the original steering box as all that's now in the way is the turbo actuator. When I remove the engine I will mock up a new bracket ad flip the actuator upside down. Click image to enlarge 330D air con pump fitted Click image to enlarge 330D PAS pump Click image to enlarge contact on the actuator Click image to enlarge

24th Mar 2023 3:15pm

BrickBox Member Since: 05 Oct 2021 Location: Wales Posts: 798	2008 2.4 110 Utility Station Wagon XS.
24th Mar 2023 4:28pm

shanecl Member Since: 20 Mar 2013 Location: Louth Posts: 494	i seen we've gone for the same colour , not mad on the grill being black
28th Mar 2023 8:11pm

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