M57/M57N swap definitive guide
M57/M57N swap definitive guide
E30/E34/E36
Since we were getting quite a few questions about swaps in to these three old timers, we have decided to make a list of dos and don’ts. If you are thinking about doing such a swap this might be interesting and helpful.
Oil sump/pan
Even before you have to worry about engine electrics the elephant in the room is engine placement and oil pan situation. While on E36 everything is quite simple, the other two chassis have a hard time fitting in the new oil pan. Loads of people on the internet will say, that E38 730D oil pan is a great solution. The harsh reality- E38 sump is only a suitable option if you are willing to move everything 5cm closer to the front of the car. That includes: the engine itself, gearbox, engine mounts. On top of that you will need to make your driveshaft longer and make a new gear lever link. After doing all that hard work, you will most likely find, that your viscous coupler does not fit between the engine and radiator.
An easy and solution for this problem is to get a modified E34 2.5TDS oil sump (you can contact us and we will source you a modified sump).
Pictures of the modified E34 sump:
Another solution, although quite a bit more expensive- modifying E38 730D sump like in the pictures below: 
The oil pick up has to be modified too. It will only take you a few hours to make it if you have a welder and a grinder. Note, that this only applies for E34 and E30 models. E36 does not need modified oil pick up or oil sump.
Engine mounts
This is kind of an easy problem to solve, here is a list of what engine mounts you will need to use:
E30- Does not need custom mounts, e46 330D engine mounts will do just fine.
E34- Right side engine mount should be taken from E34 2.5TDS engine. Left side engine mount will either have to be made custom or you can search for E38 730D engine mount. People have been using them with moderate success.
E36- Does not need custom mounts, e46 330D engine mounts will do just fine.
Gearbox
If your newly acquired M57 engine is going in to previously TD or TDS BMW there is not a lot to worry about if you want to keep your stock transmission. TDS gearbox can take a beating and will hold up if you are not throwing a crazy stage 9+ tune at them. They will hold up to around 700nm just fine. If, on the other hand, you want to use 6 speed gearbox from E46 or any never models, you will most likely have to make a new gearbox crossmember and modify your driveshaft.
Electrics
You can use one of our standalone or plug and play loom options. Plug and play looms for all the three mentioned models are available on our website.
You will need to connect relay for whatever loom option you choose. We recommend upgrading to a higher current relays and thicker automotive grade wire.
Keep in mind, that your existing gas pedal wont work. You want to get a gas pedal together with your engine.
If your car is a pre lci version (e34 and e36) you will need to buy lci TDS instrument cluster in order to get the tacho working right. If your cluster is pre lci version your rpm’s will be shown in half (engine speed: 1000rpm, tacho shows 500rpm).
Fuel delivery system
All BMW common rail diesel systems require pre-supply pressure in order to work properly. Generally, you will only need one additional pump to do the job as BMW has already installed in tank fuel pumps in these cars. You will need to connect your new pre-supply fuel pump to the existing fuel feed line. Get yourself a few meters of 8mm fuel line. Picture of the pre-supply pump is shown below. We only recommend using OEM BMW parts.
You will need to install fuel radiator. A lot of people think, that this is an unnecessary part, when in fact, it is one of the most crucial pieces of the fuel system. If you have your engine remapped or like to push it to its limits, the is a high chance of fuel starting to boil inside the tank and fuel lines. This will both: reduce your engine power and is a potential safety hazard.