Metric Mechanic M42 M44 Engine Series

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Metric Mechanic M42 M44 Engine SeriesOne of Metric Mechanic’s NEW Engine SeriesIntroductionOften the 4 Cylinder BMWsare overshadowed by their 6Cylinder cousins of the samemodel. For example, the 1990318is can get over-looked infavor of the 325i or M3. Thesame goes for the 318ti and1.9 liter Z3. But at MetricMechanic, we look at the 4Cylinders as junior models ofthe M cars. The E30 318i useslighter scaled down drive traincomponents than the E30 M3.The E36 318ti & Z3 continuethis theme through smallermore compact bodies. All the4 cylinder car models havelightweight bodies with lightweight engines, transmissionsand differentials. Weight is notonly the enemy of accelerationbut also handling and braking.The M42 and M44 DOHC(double overhead cam) engines used in these modelshave excellent power potential. Currently, our 2100Rally Engine is good for just over 200 HP and canrip through the 1/4 miles in 14.5 sec. at 98 mph inan E30 318is. FAST for a 4 banger!The power note (the sound the engine makeswhen it approaches peak cylinder filling) comes onat 4300 rpms and the engine generates very strongpull to its 7700 rpm redline. Even below 4300 theengine has a decent amount of torque which makesit a great daily driver capable of 30 mpg in highwayuse. Now for a closer look at the new MM “BabyM3 Killer Engine”.Anatomy of our M42 EngineMetric Mechanic 2000 Sport Engines use ourlightweight forged alusil pistons along with the stockconnecting rod and 81mm stock crankshaft. MetricMechanic Rally Engines are designed and built tobe the fastest street engines that we sell. They arebasically full race engines de-tuned by dropping thecompression and camming slightly.The internals are beefed up by again using lightweight but strong forged alusil pistons as well asforged 4340 Chrome Moly custom rods of “H” or“I” Beam design, and 88mm forged steel crankshafts.These components greatly extend the life of theengine and make it virtually bullet proof.2100 Rally engine on the hook ready for installationCopyright June 2012 by Metric Mechanic Inc 505 East Main, Richland, MO 65556PH: 573-765-1269 FAX: 573-765-4216,, www.metricmechanic.comPage 1

2100 Rally Acceleration Graph1991 E30 318is with Metric Mechanic 2100 Rally M-42 Engine“Baby M3 Killer!” Weight is the enemy of acceleration, braking and handling.The M42 engine is already light - but we make it POWERFUL! The MetricMechanic gang couldn’t stop talking about this car! Our comments were:“More power than the factory ever intended!” “How many cars can doalmost 100 mph in a 1/4 mile and 30 mpg in highway driving?” “The Lotusof BMWs, a powerful engine coupled to a lightweight body and drive train.”Page 2Copyright June 2012 by Metric Mechanic Inc 505 East Main, Richland, MO 65556PH: 573-765-1269 FAX: 573-765-4216,,

Anatomyof theM42/M44 2000 Sport EngineLightweight yet High Quality Strong InternalsDescriptionTop: the 2000 Sport bottomend components include eitherthe M42 81mm forged steelcrankshaft or the M44 83mmcast crankshaft.Shown right: M42 rods at610 grams, optional M44 rodsat 540 grams on the right.Both are 140mm long.Left Center: our MM slittedlightweight forged alusil pistons at 310 grams and taperedwall wrist pins at 89 grams.The ring pack uses a 1.5mmMoly compression ring, a1.5mm iron scrapper ring anda 3mm three piece oil ring.MM M42/M44 2000 Sport Bottom End Components (see below for M44 crankshaft)Piston and RodLeft: M44 2000 Sport Engine crankshaftRight: M42 2000 Sport Engine crankshaftM42/M44 CranksThe crankshaft on the left is used in the ‘96, 1.9liter M44 engine, has 4 counterweights and weighs28.5 lbs. This crank is used in OBDII engines andemploys a 60 tooth timing wheel that’s attached tothe 4th counterweight. The crank on the right is thepre ’96 M42 forged steel crankshaft, has 8 counterweights and weighs 29.5 lbs.By lightening up thereciprocating mass, anengine’s longevity canbe greatly increased. Ina Sport Engine, this isdone by reducing thepiston and pin weightby 15% over stock whichin turn increases rod lifebecause it is not bearingso much weight. Also itreduces the load on therod bearings and crankshaft. With the M441.9 liter rod and MMSport piston shown tothe left, the reciprocating mass is only 965M44 2000 SportPiston Rod Assemblygrams. But with a stockM42, 1.8 liter rod, themass is 1015 grams - 50 grams more! Using the 1.9liter rod is an effective option towards reducing thereciprocating mass in an M42 engine. These rodshave a bearing cap that measures .275” (7mm) at thethinnest point. We check their condition closely for“out of roundness” because the thin bearing cap cancause the big end of the rod to knock out of round.Once out of round, the rod bearing cap will usuallyfit loosely on the rod, which leads to fatigue.Copyright June 2012 by Metric Mechanic Inc 505 East Main, Richland, MO 65556PH: 573-765-1269 FAX: 573-765-4216,, www.metricmechanic.comPage 3

M42, M44 PistonsDecades of Experience & Research have led to MM’s Piston DesignsLeft:M42/M44 2000 SportPiston for use withthe stock rodMiddle:A 2100 Turbo Pistonused with our MM“H” Beam RodRight:The 2100 Rally pistonused with MM Ultralite“I” Beam RodHow MM Pistons GreatlyExtend Engine Life!A high quality properly designed forged piston,more than any other engine component, can greatlyincrease the life of a High Performance or RaceEngine. Engine life, is curtailed by the upper compression ring hammering out the ring groove andparts fatigue caused by a heavy reciprocating mass.A forged piston is 40% stronger and can be made15% - 20% lighter than a cast piston - when designedproperly. Although a forged piston is the perfectsolution, average forged pistons (not ours) do havedisadvantages. Their expansion rate is 35% - 50%more than a cast piston and requires .0040” clearance or more. This much clearance creates high oilconsumption (250-500 miles/quart) and causes thepiston to rattle on cold start-up.Consider this in light of the fact that high revvingheats up the piston, requiring more cylinder wallclearance to accommodate the expansion. When webegan development of our HiPerformance Engines in1984, we quickly understood the benefits of switching to the Forged Alusil Piston. These early pistonswere graphite coated to reduce cylinder wall scuffing. During the engine break-in period, the coatingeffectively wore off. Many such engines, under harduse, are still performing with over 200,000 miles onthem. Despite this success, we felt certain that theremust be an even better way to achieve tighter pistonto cylinder wall clearance.Page 4Metric Mechanic Slitted PistonsThen in the early ‘90s, we completed developmentof our “Slitted Piston” technique which involvesmachining a horizontal slit into the piston just underthe oil ring groove. This slit keeps piston crown heatfrom transferring directly to the skirt by conductingit initially to the quite massive pin boss which actslike a heat sink. This interruption along with thelonger traveled path, helps the heat dissipate; allowing for cooler skirts that expand less. This MM slitalso reduces the expansion rate of our Forged AlusilPiston from 35% to only 5% over that of a stockpiston and is the principle reason for our tight clearances. Generally, we run .0020” - .0025” clearance onour Sport Engines and .0023” -.0028” on the RallyEngines. This keeps oil consumption low and pistonrattling to a minimum on cold start-ups.Metric Mechanic Boosted PistonsA primary concern with Boosted engines is pistonmeltdown. In order to avoid piston meltdown weincrease the crown thickness by 2 mm, lower the topring groove, and use 4mm wide high radial tensionoil rings. The piston pin wall is thicker for addedstrength and it weighs 105 grams. The total pistonand pin weight is approximately 90 grams more thana Rally piston used in a normally aspirated engine.Copyright June 2012 by Metric Mechanic Inc 505 East Main, Richland, MO 65556PH: 573-765-1269 FAX: 573-765-4216,,

M42/M44 Cylinder Head & ComponentsPorted Head, Surface Turbulence Parts and Assembly ComponentsM42 Head with Metric Mechanic modifications, ready for final assembly. Shown left to right is an Hydraulic Lifter 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 of 6mm Surface Turbulenced Intake and Exhaust ValvesTour of the MM Cylinder HeadMM 100mm Head BoltsCurrently our M42/M44 heads flow 6% overthe stock head. Pre ’93 M42 heads are convertedfrom 7mm to 6mm valves for added flow and lighterweight. Our shorter valve guide increases flow overthe high side radius of the port. Seats are machinedwith three select seat angles determined during flowbench testing. A 45 angle machined into the seatmatches the valve head diameter. We also modifythe intake valve back-cut angle to increase flow. Andwe add our patented surface turbulence concentricgrooves to the valve itself. For over 16 years, thistreatment has proven to increase flow at low lifts.An added benefit is that they help atomize fuel bytumbling air flow over the valve surface and pullingfuel particles off the back of the valve.We use a special 100mm longsocket head bolt. The stocktorque to yield head bolts are90mm long. We torque ourhead bolts down to 64 ft. lbs.These longer bolts spread theload along the cylinder wallto reduce wall distortion andunlike the factory head bolts,these bolts are re-usable.Copyright June 2012 by Metric Mechanic Inc 505 East Main, Richland, MO 65556PH: 573-765-1269 FAX: 573-765-4216,, www.metricmechanic.comLeft: MM 100mm longSocket Head, Head BoltRight: Stock 90mm longTorx Head, Head BoltPage 5

M42 Sport Cam & Valve Train ComponentsComparing Intake and Exhaust Cams used for a Broad Power BandM42 Sport CamsOn an MM 2000 Sport Engine, we camup the intake side (258 Duration/11.15Lift) quite a bit more than the exhaust.Using a hotter intake cam, increases RPMsand enhances top end performance whilekeeping the stock exhaust cams, maintainsthe mid range and bottom end torque. Inthe end, this cam combination makes foran engine with a broad power band. Seecam chart lower left.M42 256 Shrick CamsThe Shrick cam set shown lower rightis basically an E36 M3 intake cam copy.Comparing the MM Sport Camswith Shrick CamsOn the surface, by simply comparingintake duration at .005”, our cam doesn’tlook that much hotter with the MM atMetric MechanicSport Cam for the M42 Engine258 Intake. 6258 and the Shrick at 256 - a mere 2 advantage. But an engine takes in mostof it’s air when the cam has the intakevalve open to .300” lift or more. Dueto faster ramp speeds, our cam has 124 duration versus the Shrick 112 durationat .300” lift. By having an additional 10%more duration at the nose of the cam, theengine will continue to make power 10%higher in RPM. Also, a larger engine willneed more cam duration and lift. A 10%larger engine will need 10% more noseduration on the cam at .300” lift to hitthe same peak RPM point.In the past, most manufacturers ranthe same cam on the intake and exhaustside. But, when the ‘95 M3 came out,BMW chose to run their intake cam withmore duration and lift than the exhaustcam. They used an intake cam with 256 duration and 10.35mm lift (same as theShrick 256 Camfor the M42228 Exhaust258 228 246 216 242 212 238 206 224 188 202 168 166 128 124 76 64 --.439”.356”11.15mm 9mmShrick) but it alsohad 25 of VANOSadded to the intakecam. And theyused milder a 235 exhaust cam with9.7mm lift alongwith VANOS toincrease the low andmidrange torque ofthe engine.So by runningtwo different lobeswhere the intakecam is larger byabout 15% overthe exhaust cam,the engine developsa much broaderpower band. This isalso what we do.Engine256 Intake. Exhaust256 256 242 242 236 236 232 232 215 215 194 194 154 154 112 112 30 30 .408”.408”10.35mm 10.35mmCopyright June 2012 by Metric Mechanic Inc 505 East Main, Richland, MO 65556PH: 573-765-1269 FAX: 573-765-4216,,

M42 Sport Cam & Valve Train ComponentsUpgraded Valve Train ComponentsMetric Mechanic - M42 Sport Cam Timing MapIntake Cam - 258 Dur. / 11.15mm Lift at .005” - Opens 10 BTDC - Close 68 ABDCExhaust Cam - 228 Dur./ 9.0mm Lift at .005“ - Opens 41 BBDC - Close 7 ATDCValve Opening During Overlap at TDC .Intake .020” (.5 mm).Exhaust .015“ (.4 mm)TDCIntakeOpens at10 BTDCE xhaus tUses Hydraulic LiftersMM Heavy DutyLifter BucketExhaust Cam - 228Intake LiftOff Seat.020” ATDCIntakeExhaust LiftOff Seat.015” ATDCIntakeClosesat 68 ABDCNo Valve AdjustmentIntake Cam - 258MM “Bee Hive” Valve Spring with Lightweight 6mmRetainer and MM Heavy Duty 35mm Lifter BucketExhaustCloses at7 ATDCMetric MechanicBee Hive Spring & RetainerExhaustOpens at41 BBDCBDCOur 35mm Lifter Buckethas a harder nitrided crownmaking it more wear resistant.The lifter spring is stiffer (seespring on left in Photo) to reducelifter bleed-down and help thelifter track the cam profile athigher RPMs. When an engineexceeds 150,000 miles and it’srebuild time, we suggest considering new hydraulic lifters.TDCBDCBTDCATDCBBDCABDCTop Dead CenterBottom Dead CenterBefore Top Dead CenterAfter Top Dead CenterBefore Bottom Dead CenterAfter Bottom Dead CenterMetric Mechanic’s use of the “BeeHive” is a preference that evolved out ofexperience with three previous springschoices. Because spring rate is very critical in making the hydraulic lifter work athigh RPMs. When using cams with higherlifts and faster ramp speeds (like our camdesigns) we are continually researchingfor better springs.Our “Bee Hive” springs and retainers are 25 grams lighter than the stockdual spring set-up. The 6mm retainerwe use is much stronger than the BMWfactory 6 mm retainer. For instance, our6mm retainer can take up to a 310 lb.load before the keepers pull through theretainer. The factory BMW 6mm retainerfails at 185 lbs. We have taped a missedshift where the tach was just shy of 9,000RPM with no incident of bent valves.35mm Lifter BucketsComparisonsMM LifterNitridedHeat TreatedStockHeatTreated54c48cCrown Thickness.0957”.0933”Wall Thickness.039”.035”Lifter SpringWire Diameter.038”.031”Crown TreatmentRockwell Hardness(C-Scale)Copyright June 2012 by Metric Mechanic Inc 505 East Main, Richland, MO 65556PH: 573-765-1269 FAX: 573-765-4216,, www.metricmechanic.comShows the hydraulic lifter and springremoved from the lifter bucket.MM to left, stock to right.Page 7

Anatomy of the M42 2100 Rally EngineRally Engine Part Descriptions2100 Rally Crankshaft, Pistons and Rod BearingsMM’s 2100 Rally engine isbuilt with an 88 stroke crank,chain sprocket, harmonic balancer hub, plus larger crankbolt & washer. Rods are lightweight forged 4230 ChromeMoly Steel, shot peened andfully CNC machined. Shownhere are 525 gram “H” beamrods. MM Ultralite “I” BeamRod weighs 475 grams - stockrod 610 grams. Pistons are 310gram forged Alusil (13% silicon content) 310 grams. Stockpistons weigh 360 grams.Adding an extra Keyway Groove to the 88mm CrankshaftLeft: 88mm Crankshaft, Right: 89.6mm CrankshaftBoth these cranks, originally from a 2liter European Diesel, need modificationsbefore they can be installed in the M42 orM44 Block. Shown left is the earlier version, an 88 stroke with 8 counter weightswhich is easier to adapt for the engine.The later crank on the right has an 89.6mm stroke with 4 smaller counterweights.Because this crank runs with a counterbalance system, it is far more difficult toadapt in. The needed adaptors are shownabove with the cranks.Page 8The 88 stroke crank musthave the nose turned downand a second keyway addedto secure the chain sprocketand front harmonic balancerhub. Close-ups are shown ofthe machining process (above)and the end result to the left.Crankshaft Nose adapted toaccept the Stock Crank SprocketCopyright June 2012 by Metric Mechanic Inc 505 East Main, Richland, MO 65556PH: 573-765-1269 FAX: 573-765-4216,,

M42 M44 RodsMetric Mechanic Rod Line-Up: the usual prospects!Far left at 140mm long isthe M44 540 gram rod. Next,an 140mm long M42 Rodthat weighs 610 grams. Theseare used in our 2000 SportEngines. The third rod is MM’sUltralite “I” Beam rod, 138mmlong and only 475 grams, usedin our 2100 Rally engines.Fourth on the far right is theMM “H” Beam rod. It’s also138mm long, weighing in at525 grams. This rods is generally used in boosted engines.From Left: M44 Stock Rod, M42 Stock Rod, MM Ultralite “I” Beam and MM “H” Beam RodsOur MM Rally rods shown to the left,are much lighter and twice as strong asthe stock production rods. Forged from4340 chrome moly steel, makes themsuperior in strength to billet rods. Thenthey are fully CNC machined to sculpture down excess weight and finally shotpeened to improve surface strength. Theyare capped off with 3/8” ARP bolts. Thesmall ends of each rod are coupled tothe piston with a 21mm lightweight 80gram wrist pin. By comparison, the stockpiston pin weighs 105 grams.Benefits of Reducingthe Reciprocating MassLeft: MM Ultralite “I” Beam Rod Right: MM “H” Beam RodWrist Pins: Left 21mm, 105 gram Turbo,Middle 21mm 80 gram Rally,Right 22mm tapered wall 89 gram SportReducing reciprocating mass weight(piston & rod assembly) has a far greatereffect on acceleration than reducing therotational mass. Lightening a rotationalmass component such as a flywheel,comes into play only under accelerationbut the reciprocating mass is constantlyaccelerating and decelerating. At 7000rpm, the piston and rod assembly is goingfrom 0 mph to 100 mph and back to 0mph - 14,000 times in one minute sincethe piston changes direction twice at thetop and bottom during one revolution.The jerking motion against the pistongoes to 1500 G-Force. Using a lightweightreciprocating mass assembly will not onlymake an engine spool up quicker but itwill greatly increase its reliability.Copyright June 2012 by Metric Mechanic Inc 505 East Main, Richland, MO 65556PH: 573-765-1269 FAX: 573-765-4216,, www.metricmechanic.comPage 9

M42, M44 Oiling SystemAmple Oiling - the “Life Blood” of a Healthy Performance EngineOiling Problems Inherent in the stock M42 M44 EnginesOil Pressure Loss from Failed Pan Gasket Thrust Bearing FailuresThe oil pump is driven off the front of the crankshaft and sits in the front housing. The oil pan sealsbetween the oil pump and the oil pump pick-up.Oil pan bolts are hidden inside the oil pan. Sometimes they’ll come loose and fall down into the oilpan. When this happens, air gets drawn in betweenthe pump and the pick-up from the loose oil pangasket (loosened by the dislodged bolts). In the endthe engine looses it’s oil pressure and the oil pumpwon’t prime up.MM Solution for Failed Pan GasketOur oil pan gasket is reinforced by a silicon sealing bead directly on this critical pick-up point. Wealso use Blue Loctite on the internal oil pan bolts toprevent them from working loose in the future.Stock M42 M44 engines only have a thrust surface on the top Main Bearing. Because of this limited thrust area, the thrust surface can wear out.MM Solution for Thrust Bearing FailureWe use main bearings with a thrust surface onboth the top and the bottom.Worn out stock thrust bearing from an M42 engine.360 Main Bearing Oiling System: double thrust bearings.High RPM Oil StarvationThe stock main bearings have about a 200 oilinggroove and oil is shut off to the rod bearings frombottom dead center to top dead center. This causesoil starvation at high rpm.MM Solution for High RPM Oil StarvationThese bearings also feature a 360 oiling groove sothe rod bearing has a constant supply of oil.Using a millingmachine andcustom keywaycutter .140” wide,we machine inthe new lock tanggroove to acceptthe 360 oilingmain bearings.The bottom main bearing cap has two narrowlock tang grooves. The 360 Main Bearings thatwe use, have a single lock tang that is 3.5mm wide.Therefore the stock bearing cap must be modified toaccept the wider lock tang.Page 10360 Oiling Main Bearings Installed.Copyright June 2012 by Metric Mechanic Inc 505 East Main, Richland, MO 65556PH: 573-765-1269 FAX: 573-765-4216,,

Oiling Systemcontinued & theTiming ChainRod Bearings, Timing Chain & Windage Tray Scrapper SystemUpgrading the Rod BearingsCurrently, we use one of three rod bearings inour M42/M44 engines. The stock aluminum facedbearing on the right works well in our Sport engines.Next is a heavy duty tri-metal rod bearing with athin Babbit facing, copper underlay and a steel backing. This bearing is used in our daily driver Rallyengines. Shown right is the same bearing but witha Teflon coated face which increases bearing life bythree times under race conditions. These bearingsare used in our Driver’s School MM Rally engines.Remember, upon request these Teflon Coated bearings can be used in any Metric Mechanic engine!E30 2100 Rally Windage Tray/ScrapperA windage tray’s function is to separate the crankshaft from the oil in the sump and the built in scrapper is used to pull off oil spray from the crankshaftand deposit it back into the oil sump. The windagetray also keeps the oil level in the pan calm andinsures that the pick-up remains submerged. Furthermore, by reducing oil drag on the crankshaft,the engine gains a couple more HP. Our WindageTray/Scrapper Bar System is an additional 350 andavailable only to those who purchase an engine fromus. We cannot sell it as a separate unit because itrequires custom machining and fitting. The windagetray shown below does not apply to the E36 M42/M44 because they come stock with oil pans thathave a magnesium windage tray built right in.Left to Right: Stock Aluminum Faced Bearing, Heavy Duty TriMetal, Heavy Duty Tri-Metal Bearing with Teflon Coated FaceSingle Row Timing Chain ConversionFor years we have used single row timing chainson the M10, M30 single overhead cam engines. Theyhave proven to be extremely reliable to the pointwhere we trust them more than the Double rowchain. Yes the dual row is physically stronger but dueto the centrifugal force of the spinning chain, thesheer mass of the double row chain can cause thechain links to stretch and wear out and the chain’swhipping action can also cause excessive wear on theguide and tensioner rail. Converting to the singlerow chain reduces the rotating mass of the chain andsprocket by about 2 lbs and to-date we have neverhad a chain failure from this modification.Adds 200 to the cost of any M42 M44 engine.Frontal View of reversed Block showing Windage Tray on underside.Machined singlerow sprocket set foruse in our M42M44 engines.Left is the MM Single Row Sprocket and ChainRight is a Stock Double Row Sprocket and ChainCopyright June 2012 by Metric Mechanic Inc 505 East Main, Richland, MO 65556PH: 573-765-1269 FAX: 573-765-4216,, www.metricmechanic.comPage 11

MM Rally Cam & Valve Train ComponentsUpgraded Valve Train ComponentsMetric MechanicRally Cams for the M42 Engine272 IntakeIntake Cam - 270 Dur. / 11.4mm Lift at .005” - Open 20 BTDC - Close 70 ABDCExhaust Cam - 250 Dur. / 11.15mm Lift at .005“ - Open 55 BBDC - Close 14 ATDCValve Opening During Overlap .Intake .025” (.63 mm).Exhaust .020“ (.51 mm)TDC272 258 260 246 254 242 252 238 234 224 212 202 174 166 132 124 76 64 .448”.439”11.4mm 11.15mmIntakeOpens at20 BTDCus tE xha. ExhaustMetric Mechanic - M42 Rally Cam Timing MapExhaust Cam - 240Intake LiftOff Seat.032” ATDCIntake Cam - 264IntakeExhaust LiftOff Seat.028” ATDCExhaustCloses at14 ATDCExhaustOpens at55 BBDCRally Cam DescriptionIntakeClosesat 70 ABDCOur Rally cams pull strong all the wayto their 7700 redline in our 2100 RallyValve AdjustmentIntake.011” .101Engine. These cams are rather top endExhaust .013” .001happy but will pull strong from 4300 rpmswhen combined with our pulse chamberintake manifold. These cams need to beused with our “Bee Hive” valve springsand lightweight 6mm retainers. The valvetrain should be lightened up with 6mmvalves. MM’s heavy duty hydraulic lifterbuckets work well with our Rally cams forhigh RPM maintenance free operation.For extreme high RPM running, switchover to our MM Mechanical Lifter BucketSystem. Shim pads are from an E46 S54engine. Valve adjustment is .004” to .005”Bee Hive Spring, Retainerwhen used with a hydraulic cam.& Stock Spring PerchPage 12BDCTDCBDCBTDCATDCBBDCABDCTop Dead CenterBottom Dead CenterBefore Top Dead CenterAfter Top Dead CenterBefore Bottom Dead CenterAfter Bottom Dead CenterLeft: MM Heavy Duty Hydraulic LifterRight: MM Mechanical Lifter with shim padCopyright June 2012 by Metric Mechanic Inc 505 East Main, Richland, MO 65556PH: 573-765-1269 FAX: 573-765-4216,,

Lightening the M42 Valve TrainReduced by Over 50 Grams per Valve Assembly!Copyright June 2012 by Metric Mechanic Inc 505 East Main, Richland, MO 65556PH: 573-765-1269 FAX: 573-765-4216,, www.metricmechanic.comPage 13

M42 E30 Pulse Chamber Intake ManifoldIncreasing Bottom End and Mid Range TorqueM42/E30 PulseChamber IntakeManifoldOurMMPulseChamber Intake Manifold greatly increasesbottom end and midrange torque in the M42engine. When lookingclosely at the base ofthe “C” runners on anM42 E30, capped offtube extensions are visible. We call these pulsechambers.How Does theManifold Work?After the intake mixture (fuel and air mixture) enters a cylinder,the intake valve slamsshut. In the stock manifold, the intake mixture starts to recoil offIntake Manifoldthe back of the intake PulseonChambera 2100 Rally Enginevalve and back-flows upthe intake runner to the plenum. But with a pulsechamber manifold, the intake mixture goes straightback into the pulse chamber because that is the pathof least resistance. Next the mixture recoils off theback of the capped-off tube (the pulse chamber)and heads for the back of the intake valve readyto enter the engine when the intake valve opens.Since the intake mixture is ready to go into the cylinder, the cylinder filling is increased and the enginemakes more power. From past Dyno testing, we canclaim a 15% increase in midrange torque with thismanifold.Side View of the PulseChamber Intake RunnerPage 14Copyright June 2012 by Metric Mechanic Inc 505 East Main, Richland, MO 65556PH: 573-765-1269 FAX: 573-765-4216,,

M42/M44 Lightweight Flywheel & Clutch AssemblyBest Performance Modification for the MoneyLeft to Right: Lightweight Flywheel & Bolts, 228mm Disc with Sprung Hub, 228mm Pressure Plate and Throw Out BearingDescriptionFrom the factory, M42/M44 engines use largeheavy dual mass flywheels with 215mm clutch assemblies. In proportion to the engine displacement, wethink this flywheel sets the record for being theheaviest BMW flywheel scaling in at a massive 28.25lbs. We replace it with a single mass flywheel weighing 11 to 11.5 lbs. and upgrade to a 228mm clutchassembly.The SignificanceThe stock 215mm clutch can take up to about 155ft. lbs. of torque. The 228 clutch assembly we usecan handle up to about 230 ft. lbs. of torque. Goingto a 228 clutch will virtually eliminate any need fora clutch replacement. This amount of “overkill”reduces the probability of ever having to replace theclutch. For the money, a lightened flywheel with 228clutch assembly is the best performance modification you can do to an M42 or M44.How a Lightened Flywheel WorksWhile an engine revs, the flywheel creates a parasitic drag on the engine’s ability to accelerate. Thefaster the flywheel is accelerated, the greater thepower loss to the engine.For example, a pair of tests on a 3700, first withthe stock 23 lb. and second with the flywheel lightened down to 12.5 lbs. revealed an impressive gain.When accelerated at 1500 RPMs per second, theengine picked up 17 HP with the lightened flywheel.Consider this: 1500 RPMs per second is equivalentto a 1st gear acceleration. Here’s another way tolook at it: every pound removed from the flywheel,is comparable to taking 15 lbs. off the body weight.SummaryInstalling a lightened flywheel does not generatemore HP in an engine. It’s more like the reductionof a loss.Copyright June 2012 by Metric Mechanic Inc 505 East Main, Richland, MO 65556PH: 573-765-1269 FAX: 573-765-4216,, www.metricmechanic.comPage 15

2000 Sport M42 Engine - Spec SheetFor the Enthusiastic Street DriverMM 2000 Sport EngineDisplacement 1925 ccBore x Stroke 87mm x 81mmCompression Ratio 11.0:1Horsepower 170 @ 6500Torque 145 @ 4500Redline 7000 rpmBlock ComponentsCrankshaft Stock 81mm stroke forged steel with 8 counterweights, 29.5 lbs.Rods Stock M42/1.8 rod, 595 gramsOptional: Stock M44/1.9 rod, 540 gramsPistonsMM 87mm Lightweight Forged Alusil Piston vented skirts11.0:1 Compression Ratio/ 310 gramsStock Cast Piston 10.0:1 Compression Ratio/ 360 gramsRings 1.5mm Moly Top, 1.5mm 2nd and 3.0mm3 piece Oil Ring (low radial tension design)Piston Pin 22mm tapered wall, 89 gramsStock 22mm / 105 gramsOi

Metric Mechanic M42 M44 Engine Series One of Metric Mechanic’s NEW Engine Series Often the 4 Cylinder BMWs are overshadowed by their 6 Cylinder cousins of the same model. For example, the 1990 318is can get over-looked in favor of the 325i or M3. The same goes for the 318ti and 1.9 liter Z3.

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COMPETENCY BASED CURRICULUM INSTRUMENT MECHANIC (Duration: Two Years) CRAFTSMEN TRAINING SCHEME (CTS) NSQF LEVEL- 5 SECTOR –ELECTRONICS AND HARDWARE . INSTRUMENT MECHANIC (Engineering Trade) (Revised in 2019) Version: 1.2 CRAFTSMEN TRAINING SCHEME (CTS) . The Instrument Mechanic trade under CTS is one of the popular coursesdelivered

36 143 Leave for Union Business 31 37 145 Military Leave – Short Tours of Duty 31 38 146 General Conditions 32 . Mechanic Auto I . Mechanic Auto II . 8 Mechanic Blacksmith II . Mechanic Electronics I . . the basis of individually signed voluntary checkoff authorization cards on forms t

Annual Men’s Day Sunday, October 26, 2008 Order of Service Devotion Men’s Day Praise Team Responsive Reading Psalm 1 Congregational Singing This Little Light of Mine Selection Men’s Day Choir Altar Prayer Dance Selection Creations of God Announcements Bro. Robert Shields Pastoral Observations Message Rev. Jeffery A. Lang, Senior Pastor Southside Church & International Ministries Jackson .