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What are some common issues to look out for halfway through a 1994 S52 swapped 525i engine project?

The S52 engine has a higher redline than the M50 engine found in the 525i, requiring more frequent shifts for optimal performance.

The S52's increased displacement provides about 30% more horsepower than the M50, leading to improved acceleration and top speed.

When swapping a manual transmission into a 525i designed for an automatic, the clutch pedal and hydraulic system must be installed and adjusted properly.

It is important to use a flywheel designed for the new transmission and engine configuration; using the incorrect flywheel may lead to clutch slippage or damage.

Routing the S52 engine's wiring harness into the 525i's chassis can be challenging, as the wiring for sensors, injectors, and ignition must be correctly connected.

The S52 engine's fuel system operates at a higher pressure than the M50's, requiring upgrades to the fuel pump and fuel injectors for proper operation.

The S52 engine's oil pan typically needs to be modified or replaced to clear the E34's subframe when installed in a 525i.

To maintain the vehicle's original driving dynamics, upgrading bushings, mounts, and suspension components may be necessary due to the increased power and torque of the S52 engine.

Using a performance-oriented clutch and pressure plate, such as a single- or multi-disc clutch, can improve the durability and longevity of the drivetrain, especially during high-load driving conditions.

Properly tuning the S52 engine using an aftermarket engine management system, like the MS3 ECU, can optimize fuel delivery, ignition timing, and other parameters to match the engine and vehicle modifications, enhancing overall performance and drivability.

The ZF 5-speed transmission used in the S52 engine swap should be checked for wear and damage, as it may have been previously used in a high-performance or high-mileage application.

Upgrading the differential to a limited-slip unit, like the 323 LSD, can improve traction and handling, especially during aggressive acceleration or cornering.

The exhaust system should be upgraded to accommodate the S52 engine's increased performance and to meet noise and emissions regulations in your area.

After swapping the S52 engine, it is essential to re-align the front and rear suspension to ensure even tire wear and proper handling characteristics.

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