New X5 4.4 Owner Resto *long thread with pic dump*

[mam4.6]

Just WOW! Very impressed...

Now take it the extra mile and go buy some IS flares and diffusers, and 87s. I would dig me a white IS!

[Deansbimmer]

Thanks guys!

I don't work for BMW, just have been around them since my first car. I do run a used ///M parts business but get most of my oem parts from thebmwminipartstore.com. I've got about $2100 in parts purchased so far not including the engine core from the bonehead parts yard. That place was a model for how NOT to run a parts place. Gives me lots of job security knowing how much better I treat my customers...


I'm on a break right now from the X5 to dismantle an 08 M3 for parts, but as soon as I get to a point where I have some time, I'll get back on the X5. I have a new cluster display and new window regulators to install next. I'm on the hunt for a good trailer hitch too. The car will eventually get some body and wheel enhancements over time as the wife approves. She loves the car so far.

As far as how I trued the surfaces... I thought about making a thread about how to do it, and I still may. It's nothing new, and lots of people make similar efforts to level their parts and just make things worse... I would surely get lots of flack from people who read two sentences in about me using a sanding block and instantly throw the yellow flag at me... There's lots of "no machine shop, no care" mentality out there...

What I do is start with the right tools. Feeler gauges, a thick machinist's straight edge, a large granite block, a knife honing stone, and a 1/2x3x8" aluminum block.

The granite block is used to true my tools and periodically check them. It's true to .0001. I take the aluminum block and honing stone and true it on the granite block. I start with 80 grit PSA sandpaper adhered to the AL block and lubricated with cutting oil to do the most work in getting the surface close to true. I make 10 long passes at a time making 100% coverage on the surface at a time until it makes full contact with the surface lows, then I change to the stone for the final finish. It is easy to concentrate on the center area of the surface but if you do you end up with a bowl shaped surface. You must maintain level, even pressure. One of the heads was bowed like this, so using my straight edge frequently, I sanded more at the front/back of the head to get close, then moved to full length strokes until I had a perfectly flat surface.

The head gasket will only tolerate the head and block being out of plane by .05 mm total according to BMW. After my home brew method and a few hours elbow grease, I am well within those specs. I've done this on several BMW engines, some boosting high numbers, and they're all going strong still.

I don't claim a surface as flat and true as a machine shop could make on decking machine, but I didn't fully disassemble my block either. I will however claim a better surface RA for sealing an MLS, than some machine shops will provide... I could go on and on about people who hate-on and complain about MLS gasket failures, who later describe practices like block prep using rotary bristle discs and scotchbrite pads... Maybe I'll post a DIY thread for block and head prep.

[g300d]

Wow, that's a lot of work, congratulations on getting her running!

Now I feel bad for wanting to dump my X because of the little things.

[Pierce330]

You are AWESOME...wow, you also have the patience of a saint...

[Deansbimmer]

Originally Posted by g300d

Wow, that's a lot of work, congratulations on getting her running!

Now I feel bad for wanting to dump my X because of the little things.

I've always liked the look of the X5, even into current year models, but couldn't afford one till now. They're a ton of car for the money now, and coming down in price to affordable cash car range. lol, I say that but I had to piecemeal one together to get it... Don't dump your X if you like the car, any problem could be fixed!

[admranger]

deansbimmer: a DIY would be awesome!

PM me your parts website, etc.

[David.X5]

Diggin it! Don't let anyone talk smack about hand sanding/lapping the heads. My dad (now 90) had to apprentice as an instrument maker before going to engineering school in Germany just before and after WWII. One of their requirements was taking a raw casting and making a perfectly square and dimensioned block using just a file, square and straight edge. Taught them you can get the job done without any fancy tools...

[J.Belknap]

Great thread. I've been there with a head job, but would like to re-ring someday. Thanks for posting!

[bestvaluestore]

Originally Posted by Deansbimmer

Hey everyone! I've wanted an X5 for a long time, with a need growing lately as driving my supercharged 98 M3 sedan is not very economical for daily use. I'm online on Bimmerforums and M3post but I thought it would be cool to talk about my X5 here on the outpost so here we go!

It all started when I thought I found a steal when an 03 V8 with sport package popped up on Craigslist for $2300 non running, listed as a fuel pump failure. I got on the phone and told him I'd buy it, so he held off the other buyers and I drove two hours to pick it up.

When I arrived I could tell the games had begun because he had pulled the battery out "because he wanted to keep it". I would have brought my jump box had he told me so I could test the electrics, etc, but I knew it wasn't a runner so I continued to pay and load it up. It was raining, cold, and dark- great car buying weather.



So the next day, once home, I hook up a new battery and crank it over to feel it out. She's not a bad looker...





Listening to it I immediately know it was not a fuel pump issue, the engine was slow to crank and sounded like it had no compression strokes, so I immediately think head gasket. I did a quick compression test and quit after three cylinders had 5psi compression. I knew I was pulling a head to investigate.

So far so good... There was evidence of overheating with coolant residue around the reservoir and hood liner, and the previous owner had obviously been chasing it down for years as the cooling system had new parts all over- hoses, radiator, reservoir, etc...no part was over a couple years old...


Then I pull the head off and found carnage. Every cylinder had irreparably severe scoring... Oh boy I though...


So I think about my options... Obviously the seller knew the engine was fried and tried to mask it. I post it back on CL for what I paid, but being honest about it needing an engine....No takers for a few days. So I decided not to part it out, but to put a new engine in it. Thus begins the Saga.

I get online and look for a good engine. I have seen them grow on trees lately these 4.4's, but of course now that I need one it seems the sources have dried up. Shipping one in was proving to be the only option but I wasn't ready to pay over 2 grand for a tired engine with 100k miles or more.

I found a local yard an hour away selling what sounded like a steal- a 90k mile BMW 740iL "long block" for $700. I talk to the yard and he describes a low mile great running engine, but without the peripherals, oil pan, or intake, all wrapped up in plastic and stored indoors. Perfect, just what I was looking for. I get there and found I had been once again, duped. The engine was under a lean-to metal shed, under a bedsheet, covered in dirt and dust- no timing case, oil pan, intake, or valve covers. Completely open to the elements! I have words with the guy I talked to on the phone and tell him I drove almost two hours in traffic to find a block worth nothing more than a core refund. I told him I'd buy it at a much lower price IF I can pull the heads to check the bores for water damage. He (quite reluctantly) agreed. Of course I find damage as two cylinders were sitting in water and had rusted rings, along with timing chain rail failure (didn't skip timing though).

Lacking any other options at the time I decided to take it home with me, I had quite the sour stomach on the drive home, wondering if I had made another big mistake. I am too embarrassed to post pics of the engine as I received it, but here is one of the heads to give you an idea...


Now I plan a full engine rebuild. To give some background, I am a tech and BMW parts guy by profession and work on BMWs and built my ///M cars from the ground up and am no stranger to building engines, so I dig in. I get my wish list together and start getting all the parts together. In the down time waiting for parts, I pull the old block. So much oil leakage... Goodness...







In removing everything, I find completely worn out brakes, CV axles, front driveshaft, flex disc, and various hoses, so I add all those to the list, turning this into more of a resto.

You won't loose from all that restoration?

[crystalworks]

Originally Posted by Deansbimmer

I don't claim a surface as flat and true as a machine shop could make on decking machine, but I didn't fully disassemble my block either. I will however claim a better surface RA for sealing an MLS, than some machine shops will provide... I could go on and on about people who hate-on and complain about MLS gasket failures, who later describe practices like block prep using rotary bristle discs and scotchbrite pads... Maybe I'll post a DIY thread for block and head prep.

Amazing work in here. Much respect.

Please do post a DIY for block and head prep... I am doing a head gasket on an e36 soon and though I have done HG's before, I am always up for learning more/better ways to do something. Thank you in advance.