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Old 09-09-2020, 08:00 PM
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TriX5 TriX5 is offline
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Join Date: Dec 2008
Location: Maryland
Posts: 1,632
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Cool It runs and quite smooth too.

Dieselfan, UR welcome :-) Trying to add some details about the process that I found hard to find despite many threads on this topic.

Last week I was reading Sunny-J's thread on his maintenance adventures and I decided to order the seals for the vacuum pump as he had done from DUDMD. Arrived quickly and in order from across the country! Good service. Over the weekend I cleaned the swirl flaps with some purple power, that stuff is amazing and very strong (it dissolved the orange paint in my oil catch tray.....)

So, the parts all having arrived, I decided to start the engine up today. The vac pump comes off easily and the seals are easily replaced. Then put the EGR cooler back on and the lower intake duct. Finished tying down all the hoses and wires. Assembled the intake manifold swirl flaps and motor, EGR valve. (decided to put the throttle body after the IM was installed. Popped the IM on the engine......and realized I forgot to put the 12 seals on the intake ports.... I had only begun to tighten 2 bolts but definitely felt a bit silly. One little trick is to get the IM lined up is to keep the front of the IM lifted and spot it going on to the rear stud, then lower the front of the IM. It fell in to place easily....twice.

After wrestling with the covers I removed from above the ECU and searching for the front reinforcement bar which had fallen behind a box.... . Then the ever fun bit of re-installing the fan and the charge hose.

The motor started easily and ran quite smoothly. Not sure which of all the items I cleaned and/or replaced makes the difference but I'm sure that after 150k miles none of it was excessive. Deleted the codes with INPA and none reappeared but I have not driven it as the bottom covers are still off (plan to service the trans and do an oil change. More of this in a few days.
Attached Images
 
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2003 4.4i black ext./black int./black headliner (kid's runabout)
2014 535d X-drive, M package, silver/black interior

Sold but not forgotten:
2009 E70 35d, black ext./black int./black headliner (sold 2021)
2006 4.8iS Le Mans blue/cream int./black headliner, SOLD in 2012 sadly...

Other hardware:
2015 Cayenne S (wife's new DD and definitely wroooommmmm)
2016 Tundra 1794 edition crew cab, luxo hauler
2005 Tundra crew cab, weekend hauler. Sold after 150k very happy miles.

Last edited by TriX5; 09-10-2020 at 12:20 AM.
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