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  #81  
Old 10-30-2019, 01:26 PM
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Quote:
Originally Posted by TriX5 View Post
the kit I purchased is quite complete
Sorry if I missed it - which kit did you get?

Nice work!
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  #82  
Old 10-30-2019, 09:28 PM
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Getting close to ready for rolling the motor/trans back under the car.

I bought a kit off Amazon: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

As to the reasons for this job: I have to admit that I can't really figure out where the oil leakage came from. Most of the rubber seals are very brittle and the o-rings are also brittle. The oil in the spark plug openings clearly comes from the valve cover seals but the mess on the front of the engine has no clear single source. The chain guide wear was minimal in my view. The Vanos seals were hardened and refreshing the Vanos was necessary. So a lot of good reasons but nothing stands out overwhelmingly as near failure.

At present the trans is once again mated with the engine and the torq conv attached to the flywheel. Added fluid as much as it will take without the engine running. Put a new flex disk in the front drive shaft and cleaned/greased the splines. Also refreshed the TCase fluid.

Tomorrow the timing covers will go on and I ordered a new Crankshaft bolt for the vibration damper hub. I bought a piece of 3/8" rubber hose for the filter drain line, I don't feel like replacing the whole assembly if a piece of hose is about 5% of the price..... By Friday evening I expect to have it ready to wheel the whole assembly under the car.

Pics are of the sub-frame coming back on the cart that will carry the whole assembly back under the car. Second pic shows the engine mounted on the sub-frame. I will add a picture later of the whole thing when it is all together and going under the chassis.

The ABS module should be back on Saturday. Parts for the front suspension came this morning. I am thinking about opening the inner boots so I can pop the axles into the diff and repack the inner joints later.

The biggest challenge will be reassembling the front of the car. It is a long time since I took it off and my recollection of that is sketchy....
Attached Images
  
__________________
2003 4.4i black ext./black int./black headliner
2006 4.8iS Le Mans blue/cream int./black headliner, SOLD sadly...
2009 E70 35d, black ext./black int./black headliner (shipped to Europe)

Hmmmm, love those black headliners!

Other hardware:
2005 Tundra crew cab, son's DD and weekend hauler
2015 Cayenne S (wife's new DD and definitely wroooommmmm)
2016 Tundra 1794 edition crew cab, luxo hauler

Last edited by TriX5; 10-30-2019 at 10:12 PM.
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  #83  
Old 11-10-2019, 10:29 PM
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At last, its back where it belongs.

These last few weeks have been productive despite a quick trip to RI on Fri/Sat. College tours for my youngest. Another 1000 miles on my Gen-1 Tundra....

This morning I put the new lower control arms on, after last week completing the engine and joining it with the transmission (new flex disk went in at the same time). Putting the lower timing cover on is not a funny job and I recommend buying a 12" (thin) joint compound knife to keep the gasket down whilst sliding the cover in place. Otherwise it tends to come up when trying to put the cover in place, you have to slide it on to the front of the crankshaft whilst moving toward the engine.....

Also I found it necessary to line up the fly wheel with the torque converter so that you can put at least one bolt in before turning the engine for the second bolt. With a paint marker I marked the vibration damper on the top when I put the first bolt in and turned 90 degrees using the mark for each successive bolt which made it simple to line things up. Torquing up the new jesus-bolt (holding the vibration damper hub) was easier than expected with the 3/4" socket and breaker I purchased to undo it.

I put new inner boots on the axles (the Rein kits come with the wrong grease, pick up some inner CV joint grease from your closest Honda dealer) and filled the front diff with fresh gear oil. Also put about 6 or 7 liters of engine oil. Latter was good as I had not torqued the banjo bolt from the separator enough and it had a very small leak which materialized in the two days I was on the road.

I changed the coolant hoses behind the engine, these being the heating circuit, which are hard to get to with the engine in place.

So today I wheeled the engine back under the car, a bit of a tight fit to get it in between the flanges of the frame rails....now the engine is back in with the 6 bolts holding the sub-frame and a further 6 holding the rear transmission mount. Still need to attach the rear drive shaft properly.

Tomorrow I need to torque the bolts, put the A/C compressor on, put the steering knuckle in place, put the brakes and wheels back. Then reassemble the oil filter, coolant tank, etc. Worst will be tracing the wring back. Then comes the radiator and hoses, setting the fuel rail back on the engine. Then finally it should be ready for adding fresh fuel and (only a 1/4 tank in it now), firing it up.... I suspect that startup will be towards end of the week. (I have to do a few chores on the other vehicles including a new exhaust for the Gen-1 Tundra which has two holes and is developing a deep baritone)
Attached Images
   
__________________
2003 4.4i black ext./black int./black headliner
2006 4.8iS Le Mans blue/cream int./black headliner, SOLD sadly...
2009 E70 35d, black ext./black int./black headliner (shipped to Europe)

Hmmmm, love those black headliners!

Other hardware:
2005 Tundra crew cab, son's DD and weekend hauler
2015 Cayenne S (wife's new DD and definitely wroooommmmm)
2016 Tundra 1794 edition crew cab, luxo hauler
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  #84  
Old 11-14-2019, 12:33 PM
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Holy shit. You doing this by yourself? You give me hope that i can also one day put a puzzle like this together. I always wanted to rebuild a car. Crazy amount of work, I am surprised you are not forgetting things. I am sure I would.
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  #85  
Old 11-15-2019, 12:30 AM
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A lot more completed. Wiring is done but for the oil level sensor and starter.

Iím by myself but having ample time to do it helps me to remember where everything goes. I find that putting all the mechanical components in place helps because the wiring becomes much more obvious.

The fuel rail is on and all the hoses in the back of the motor as well. The trans is connected and I installed the front part of the exhaust (2x, at first I forgot the heat shields but remembered just as I started to bolt it up). I put the front brakes and wheels back so that i could remove the jackstands.

Still have to reinstall the mufflers and I cannot remember why I took them off.... Then the hoses and radiators have to go on at which point new gas will go in and I hope to fire it up!

After that the front bumper and headlights have to go on. At that point I can run a shakedown to assure it all works.

Then i need to overhaul the rear suspension, new inner bushings and control arms as well as int links, ball joints and stab links. My son promised to help with replacing the nav screen and finally it needs a new windscreen as it had cracked side to side before I parked it.

This will be a DD my kids will share. My 05 Tundra also needs some work but that should be about a week worth, not this type of op!

Will try to post some more pics in the next few days 😀

PS Re-attaching the A/C compressor with the engine in place is a royal pain. Should have done that after wheeling the assembly under the car but before jacking it up into place. The bolts need to be in the comp when you lift it into place, they cannot be put in after you maneuver the compressor into the bracket. Lovely bit of engineering from BMW, but then...you all knew that already!

Added some pictures of the work. One is of the inner axle joint, while replacing the boots Note the Honda grease tube). Then a look at the hose spaghetti for the heating circuit, replaced all of these. Then there is the up, up, up! Finally a picture of progress.
Attached Images
    
__________________
2003 4.4i black ext./black int./black headliner
2006 4.8iS Le Mans blue/cream int./black headliner, SOLD sadly...
2009 E70 35d, black ext./black int./black headliner (shipped to Europe)

Hmmmm, love those black headliners!

Other hardware:
2005 Tundra crew cab, son's DD and weekend hauler
2015 Cayenne S (wife's new DD and definitely wroooommmmm)
2016 Tundra 1794 edition crew cab, luxo hauler

Last edited by TriX5; 11-16-2019 at 11:00 AM.
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  #86  
Old 11-17-2019, 11:49 PM
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Weekend update

Despite a busy weekend I still got a lot done on Friday, and about an hour more on Saturday afternoon before a work related dinner. On Sunday no wrenching possible at all as I had a trip to visit an exhibit at the Smithsonian for my daughter's school project.

At any rate, I got the oil filter housing hooked up and the power steering reservoir connected/filled with ATF. The washer tank is back in and I put the coolant tank in place. The aux coolant pump had been placed back and connected a few days earlier. So far, so easy. Nevertheless, the left front corner of the engine bay is "hose central". Triple checking all the various hoses and connections is recommended to assure nothing is left "un-tightened".

Next pulled some large pieces of the car from the back of the garage and cleaned the radiators with compressed air. The disassembly of these parts is so far back in time that I had no memory of how it was put together.... After studying said pieces for 10-15 minutes I decided the A/C radiator and frame were meant to go in first. The aux fan is an easy fit on to the front of the radiator frame with two tabs holding the top and two screws retaining the bottom.

After giving the front of the engine a final check then set the coolant radiator in place and connected all the remaining coolant hoses as well as the transmission heat exchanger. Refilled the coolant and refitted the top bracket of the radiator assembly.

Next on the list: In the engine bay I only need to get the air filter installed and make the electrical connections in the right front corner of the engine bay. I plan to get the steel bumper assembly attached to the frame rails and then mount the rear mufflers, at which point starting up should be possible.

This is the last week I can work on it until the end of the month. I guess I will finish most but will still have some stuff left to do. Hope to have it roadworthy during first week of December.... I'll add a few pictures of the engine bay and front clip assembly tomorrow.
__________________
2003 4.4i black ext./black int./black headliner
2006 4.8iS Le Mans blue/cream int./black headliner, SOLD sadly...
2009 E70 35d, black ext./black int./black headliner (shipped to Europe)

Hmmmm, love those black headliners!

Other hardware:
2005 Tundra crew cab, son's DD and weekend hauler
2015 Cayenne S (wife's new DD and definitely wroooommmmm)
2016 Tundra 1794 edition crew cab, luxo hauler
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  #87  
Old 11-18-2019, 09:36 PM
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SHE IS RUNNING!!

Today pressed on with putting stuff on the front of the engine and the steel bumper carrier as well as the other components attached the bumper carrier. I put the fan, air filter, MAF etc. Also strapped the mufflers back where they should be.

Added 35 liters of gas and then the big moment was there! I fully expected to have to jumper from my p/u truck as this battery has been in the car for a VERY long while but the motor turned over just fine.

One cycle, then a second.....hmmmm, clearly the fuel system on the engine was empty but how empty? On the third cycle she caught briefly after a few seconds and then IT RAN!!

Unfortunately with an incredible screeching sound.....after searching on the internet it seems that this is an idler pulley bearing and I will order the whole unit.

Nevertheless, I am delighted it ran smoothly and started easily a second and third time. So it looks like the end of the saga is approaching fast!

Now I am out of coolant and I need some other items as well, so back to ordering stuff. :-)
Will post pics once it is cleaned up and and the remaining work is complete. Thanks everybody for the help and encouragement.
__________________
2003 4.4i black ext./black int./black headliner
2006 4.8iS Le Mans blue/cream int./black headliner, SOLD sadly...
2009 E70 35d, black ext./black int./black headliner (shipped to Europe)

Hmmmm, love those black headliners!

Other hardware:
2005 Tundra crew cab, son's DD and weekend hauler
2015 Cayenne S (wife's new DD and definitely wroooommmmm)
2016 Tundra 1794 edition crew cab, luxo hauler
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  #88  
Old 11-18-2019, 10:53 PM
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Nice work!
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  #89  
Old 11-18-2019, 11:05 PM
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can't believe i missed this thread; awesome to see it's running. I've been there with 3 different chain guide jobs; on one we forgot to reconnect the fuel rail supply line. As it turns out, 50psi on a 3/8" line will supply quite a lot of fuel into a puddle under the car!
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  #90  
Old 11-19-2019, 12:16 AM
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Thanks! It has been a fascinating process and I feel that I really know a lot more about the M62. Putting it back together after so many months was an eye opener. Yes, this can be done much faster but there were so many other things to take care of on the personal front.....

Tomorrow the rear brakes come off as they need a cleanup and I plan to completely do the rear suspension. Should be much quicker as it is quite similar to the E70 I just did.

On Wednesday I have a day away from the wrenching and on Thursday hope to receive enough parts to get it off the blocks.

On Saturday I fly out for a week but during the week of Dec 2 I should be able to complete the whole project, well, that is if an e53 is ever totally completely finished.... :-)
__________________
2003 4.4i black ext./black int./black headliner
2006 4.8iS Le Mans blue/cream int./black headliner, SOLD sadly...
2009 E70 35d, black ext./black int./black headliner (shipped to Europe)

Hmmmm, love those black headliners!

Other hardware:
2005 Tundra crew cab, son's DD and weekend hauler
2015 Cayenne S (wife's new DD and definitely wroooommmmm)
2016 Tundra 1794 edition crew cab, luxo hauler
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