E39 M5 restoration project Version 2.0

[BreakMyWindow 1870]

More progress.

Bank 1 and 2 Upper timing cases off and on, then off and on again to seat them properly. Not before the bank 2 Vanos diaphragm springs arrived though.

Bank 2 vanos unit dismantled, cleaned and new orings installed.

Vanos units installed, cam timing checked, bank 1 exhaust cam slightly off. Adjusted and then cam timing re-checked, checked again, checked once more, then checked another one time for good luck. Timing now perfect.

Vanos solenoids installed

New cam bearing oiling rail for bank 2 intake. Old one was munted, most likeley someone leaning on it while working on the engine in the past.

Radiator and other bits installed.

Cam covers, new spark plugs, earth straps, coils installed. Coolant added and a once over for any loose nuts/bolts and she's ready for firing up.

The engine started first pop, although very rattly, and lumpy. This lasted about 30 seconds and then it came right. Ran a vanos test on Bank 1. Success!

Let the engine warm up so the air bleeds from the cooling system, then on to installing the rest of the bits

Cleared all the fault codes in relation to the air mass sensors being unplugged and took it for a spin around the block. Need to check for leaks over the next few kms.

This job took me ages. Going slowly, at least 50 hours. Saved a sh1t tonne in labour however and learned a great deal about how the vanos system works in the S62, which is something I've always been keen on.

[LemonHunter 583]

Ballsy project, one of those save myself 7k if sucess or cost myself extra 7k if fail I imagine.

I feel like I'm in the stone age digging sand and rust out of my E30 and M20 while you dabble in stuff that wouldn't look out of place on a space shuttle.

[Rubix 434]

Awesome! Glad it started, good work on doing such a job yourself.

[HELLBM 1530]

Great work Martin. If you are considering a change in vocation.....

[rusteee 52]

Well done man!! What an awsome project meticulously done. Keen to see it at the next meet

[NUSTAD 243]

Congrats Martin - you have lifetime membership on your man card! Seriously great work! Now you get to enjoy it!

[hybrid 1039]

Tits dude ... good stuff.

[BreakMyWindow 1870]

Changed the radiator fan yesterday evening, the original one had a chip in it. Thanks to Hellbm for the replacement.

Done over 200kms now since the surgery, no leaks so far.

Off to get a few power runs at MCR automotive's dyno to see what she's making at the rear wheels.

[Nobimmer 694]

Awesome effort mate

[Michael. 2312]

227.5rkw is my guess.

[BreakMyWindow 1870]

Looks like the surgery has paid off with decent dyno results. Car is 100% stock.

Being quite a hot day and the dyno cell being even hotter, the sucked air temp was 51 deg C. Not ideal for getting an accurate power run.

Stock mapping retards ignition timing if the sucked air temp gets above 40 Deg C.

So I came up with an idea... The inlet temp sensor is intergrated in to the passenger side maf....

After about 10 mins the sucked air temp reading was 28deg C. Good for getting a more accurate reading.

Big fan to keep the engine cool.

Trusty old IBM stink pad with INPA and DIS to keep an eye on the temperatures

234 kw at the wheels with sucked air temp @ 31 deg C.

[Michael. 2312]

Awesome, hehe what a good guess!

Funny to think at 3,500rpm it matches what my E36 1UZ did at 5,500rpm peak.

What software are you running to pull up the diagnostics, is that just plugged into the OBDII port?

[BreakMyWindow 1870]

Youtube clip

[BreakMyWindow 1870]

Awesome, hehe what a good guess!

Funny to think at 3,500rpm it matches what my E36 1UZ did at 5,500rpm peak.

What software are you running to pull up the diagnostics, is that just plugged into the OBDII port?

Yep, plugged in to the pac-man port using a cable from ebay Lithuania.

Took me hours to get DIS working, in the end I obtained a pre-configured image that just worked and passed the API test off the bat.

[NUSTAD 243]

Nice clean curve on the dyne plot - great work! What's next.......

[KwS 2373]

love the nice linear power line. wish i could afford one of these, such fantastic cars.

[jeffbebe 1559]

Let's go driving this weekend, Martin!!

[BreakMyWindow 1870]

Nice clean curve on the dyne plot - great work! What's next.......

On to the diff input seal. Took a mate and I 2 hours this morning. Everything went smoothly and was good to see the Guibo was recently replaced.

As you can see the input seal was leaking badly and had made a mess that was not fun to clean up.

Oxygen sensors unplugged, exhaust removed as one piece, driveshaft out and then on to cleaning up baked on diff oil.

Stones caught in between the heat shield and driveshaft grinding away at the paint on the shaft

Before

After, with new input seal in place.

New gearbox oil as recommended by Kayne Barrie. The old fluid looked original, black.

Driveshaft back in, exhaust wrestled in to place and some more clean up. Job done!

Next job is to install these.

[kulgan 1042]

As usual. Awesome work.

This is one of my favourite threads.

[Michael. 2312]

The mufflers arrived????

[BreakMyWindow 1870]

The mufflers arrived????

Yeah a few weeks ago.

[Michael. 2312]

Awesome. Look forward to seeing / hearing them.

[BreakMyWindow 1870]

Might sound way too loud as there are no cats in this one. Might need some resonators in between the oxy sensors to tone it down a bit.

[Michael. 2312]

Mmmm yeah that did cross my mind.

I see they already run an H pipe before the Y resonator.

Might be quieter again if you turn it into an X, but that would change the overall tone quite a bit.

Ive still got some spare exhaust parts, those new mafnaflow cats and a pair of small resonators from an Audi S6 V10, not sure if Ill use them on the V8.

[BreakMyWindow 1870]

Some more progress.

Eisenmann race back boxes installed. No cats = Loud.

Facelift xenon headlights installed.

DSP adapter for my ipod kit picked up tonight from our forum sponsor gadgets4u.

Epic fail on the facelift LED tail lights install/swap with other M5. The metal buckets need more 'fettling' with a BFH in order for the tail light gaskets to seal against the metal. Thankfully not much rain forecasted as I now have 2 M5's with leaking tail lights :-x

After spending a good few hours drilling the bigger holes required, and re-shaping the buckets with a dead blow, checking for leaks after assembly (fail) I got fed up and decided to use this :

Waited 24 hours for it to cure. Did a leak test, still leaking. Because the other M5 is also a pre fl, the buckets were beaten with a hammer to get the fl tail lights to fit, I installed new gaskets last year and they did not leak. What's worse is having to A. remove cured urethane, and B. doing the whole job on 2 cars to ensure leak free tail lights that sit nicely. I'll get there...