So, here it is. The roots of #001, an S54 engine that was in a very sorry state. A cracked piston around the compression ring land had lead to a rattle – upon disassembly scoring was found on the bore and a new engine was sourced for the vehicle (a 94k mile, 2004 E46 M3). This is where we stepped in, picking up the engine for under £1000 with most of the ancillaries.

A sorry state, but one perfect for what’s planned. Upon further disassembly more damage was discovered – nothing that can’t be sorted, but a worrying reminder of how fragile S54 bottom end bearings are. These had scuffed the crank and so it will be having a re-grind (sizing TBC).

Crank out and it was time for a quick clean up of the block. It will be going away for boring/honing and chemical cleaning so no need to go crazy here. But we’re down to it – a bare S54 ready for some Koflach Engine Developments magic. Hopefully you guys enjoy watching this build progress as much as we will doing it!

KED Build #001 (S54B33)

• Introduction
• Part 1
• Part 2
• Part 3
• Part 4
• Part 5