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BimmerM3inGA · #3 07-20-2015, 08:43 PM

Here's a quick update on this project:

I sent the cluster to VDO Repair for diagnosis. I've spoken to the tech several times about it since, and as of now (3 weeks later) they still have it. The basic problem is that someone attempted a repair in the past by swapping the main control board and transferring the primary CPU to the new board. But in doing so, damaged the chip. Also, the replacement control board is lacking the connector for the variable redline - which is why that feature doesn't work.

The plan now is to replace the CPU chip with a new one, code the VIN and set the mileage to "0". He didn't have the software tools on hand to properly code the chip, so he ordered what he needs and that's the reason why it's taking so long.

Since I wasn't sure what to expect when I sent in my cluster, I thought it might be a good idea to have a backup plan. I found a really nice used 4.6is cluster on eBay, bought it, and sent it to VDO Repair along with my original cluster. The idea being that if mine can't repaired, I could recode the new one and use that instead. But since my original CPU is damaged, that plan won't get me going any sooner since we still need the programming tools.

Maybe I would have been better off just buying a new cluster from BMW?

Since the X5 isn’t going anywhere for a while, I decided to get it caught up on some urgent and remedial maintenance.

Urgent Maintenance #1:
One of the outer CV boots was torn, so I replaced that. I removed and cleaned the CV joint, and since it’s still in great condition, I only replaced the boot. Having plenty of time, I did it the hard way by removing the entire steering knuckle. This is a lot of extra work, but it does greatly improve access to the CV joint. It also made it possible to completely clean off all the old grease that was flung out of the torn boot.

Urgent Maintenance #2:
Oil was leaking from the Bank 1 valve cover and Bank 2 upper timing cover gaskets. I debating going ahead and having the valve covers powder coated while I had it apart, but decided to wait on that until the next time I have to take it apart. It was also due for an oil change, and I wanted to check on the condition of the timing chain guides. So after draining the oil, I removed the oil pan to check for any broken pieces of the chain guides. Thankfully, there was no evidence of deteriorating guides. With the upper timing covers off, I could see about half of the guides and also visually inspected them. Again, no evidence of failures (yet). So I buttoned it back up with new upper timing cover and valve cover gaskets on both banks, new VANOS solenoid gaskets, a new thermostat, and a new A/C compressor belt.

Remedial Maintenance #1:
With that done, and having had to drain most of the coolant anyway, I figured it was a good time to flush the coolant. The old stuff has been drained out and I filled it with distilled water for the time being until I can run the engine enough to thoroughly circulate the coolant and flush out all the old coolant.

Remedial Maintenance #2:
I wasn’t planning to change the drivetrain fluids yet (diffs, transfer case) but the big aluminum skid plate has to be removed to drain and fill the front diff. It was already off to get to the oil pan, so I figured what the hell, and took care of that too.

I’ve also thoroughly cleaned everything that was removed, or that I could get access to with other bits removed.

So as of now, it’s all put back together and ready to go except for finishing bleeding the coolant and the instrument cluster repair.

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