BMW S62 Repair/Rebuild

[DallasM5]

Past weekend I went to fill up the car and wash it down, I was sitting at a stoplight, only to find my vehicle went into limp mode. At first I thought some CPS or vanos was bad, no big deal, I was almost home and would run the codes when I got home. Shut the car when I pulled in, ran the codes and they were mostly misfires and fuel trim errors, no big deal I thought, reset them all and fired the car. Heard a constant knocking so I shut it off, and have not started the car since.

I pressurized the coolant system and cylinder 5 flooded indicating a coolant leak in that cylinder, which is where I am now, tearing off the head on my S62 in hopes that my Block is ok, which is still to be determined.

If my block is ok, then I will rebuild this motor with upgraded internals, sleeves, cams, rods, pistons, basically everything I can get my hands on before my wallet starts crying.

If the block is toast, then I plan on sitting back and evaluating exactly how much I value the car and moving from there.
Here are pics, I will update as I go along.

Special tools courtesy of BMW of Dallas
http://i5.photobucket.com/albums/y174/Ridgefootball80/engine%20repair/IMG_0418.jpg

the damage
http://i5.photobucket.com/albums/y174/Ridgefootball80/engine%20repair/IMG_0429-1.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/engine%20repair/IMG_0431.jpg?t=1240547760
http://i5.photobucket.com/albums/y174/Ridgefootball80/engine%20repair/IMG_0433.jpg?t=1240547762

The Repair/Rebuild
http://farm4.static.flickr.com/3632/3413500436_83cf6c82cd_b.jpg
http://farm4.static.flickr.com/3530/3318765394_2e5802c995_b.jpg
http://farm4.static.flickr.com/3577/3317938161_a2f7cd6b0e_b.jpg
http://farm4.static.flickr.com/3315/3318764282_79a4ed5b98_b.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/engine%20repair/IMG_0437.jpg?t=1240547769
http://i5.photobucket.com/albums/y174/Ridgefootball80/engine%20repair/IMG_0441.jpg?t=1240547773
http://i5.photobucket.com/albums/y174/Ridgefootball80/engine%20repair/IMG_0453.jpg?t=1240547888
http://i5.photobucket.com/albums/y174/Ridgefootball80/engine%20repair/IMG_0469.jpg?t=1240547912
http://i5.photobucket.com/albums/y174/Ridgefootball80/engine%20repair/IMG_0474.jpg?t=1240547914
http://i5.photobucket.com/albums/y174/Ridgefootball80/engine%20repair/IMG_0476.jpg?t=1240547955
http://i5.photobucket.com/albums/y174/Ridgefootball80/engine%20repair/IMG_0478.jpg?t=1240547983
http://i5.photobucket.com/albums/y174/Ridgefootball80/engine%20repair/IMG_0484.jpg?t=1240547985
http://i5.photobucket.com/albums/y174/Ridgefootball80/engine%20repair/IMG_0489.jpg?t=1240548026
http://i5.photobucket.com/albums/y174/Ridgefootball80/engine%20repair/IMG_0471.jpg?t=1240548108

I need to remove the thermostat housing, fuel rail, front timing cover, headers, and chain-tensioning piston. Before I can remove the head, another day’s worth of work should be enough.

-R

[Carlos]

That sux!!! Hope your back on the road soon.

[RaceMX-M3]

Good luck with this, nice to be able to diy.

[TiptronicSoldier]

cool pics bro, should be interesting to see what happens. Good luck with the fix.

[Mike CLK Black]

Sorry that it happened but great pictorial!
I love car porn!
Hope it goes smoothly.

[DallasM5]

its over, f uck my life

[sk330i]

its over, f uck my life

damn, what happened?

[BlackSheep]

When I look under a hood and cant identify anything... It must be German!

[snowball]

its over, f uck my life

damn, what happened?

The block must be toast........:thumpdown:

[Blake]

He told me 4" crack in the block.

[DallasM5]

http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0495.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0498.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0501.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0503.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0506.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0514.jpg

the end

[Crash]

Dude that sucks. Really sorry to hear it.

[LanceFitzgiben]

what's the deal raza?

[RaceMX-M3]

Sorry to hear. I had to buy a new motor for my M3 last year. I can refer you to someone that will sell you a new block for < anyone. Let me know if I can assist.

[DallasM5]

Sorry to hear. I had to buy a new motor for my M3 last year. I can refer you to someone that will sell you a new block for < anyone. Let me know if I can assist.

< anyone ay?

gimme a call tomorrow scott, sent you my number

i sourced a used block and may go that route along with another motor. either way i am going to build a bamf motor, its gonna happen, sleeves, oversized pistons, rods, crank, cams, oversized valves, and a blower. :burnout:

800hp? ;)

i want/will have this

Cryo'd block
Coated block
Custom Darten flanged steel sleeves to eliminate the concerns with the OEM Alusil coated aluminum cylinder bores
Custom spec'd CP 9.5 CR pistons w/ fabricated Teflon and Ceramic coated
Custom rings
Custom spec'd Carrillo rods
New head and main bolts
Multi-layered head gasket
Fully ported and flow matched cylinder heads
New over sized Stainless valves (1mm greater diameter)
New springs
New Guides
New Retainers and keepers
Schrick Cams
New construction of crank bearing
Micro polished crank
ESS Supercharger

[RaceMX-M3]

PM sent

[mark1281]

Geez Raza, that is a ton of work goin on there... hope all goes well

[DallasM5]

scooped up a complete motor today

so the build begins

the goal - 700HP

[RaceMX-M3]

scooped up a complete motor today

so the build begins

the goal - 700HP

Raza,

Congrats - can't wait to see your car when it's finished. :thumbsup2:

[DallasM5]

with the help of blake today, we were able to get that SOB out.

http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0591.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0592.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0594.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0615.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0635.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0636.jpg




now i have a bag of random bolts! LOL!!!
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0623.jpg?t=1241410937

[Blake]

Easy part is over

[Crash]

Looks like the cherry picker held up just fine.

[DallasM5]

Looks like the cherry picker held up just fine.

sure did, thanks for helping me put that sucker together. those instructions were useless.

whats BS is how i went out and purchased a new one and today i found 3 of them on craigslist listed yesterday.

[Crash]

Ha, that sucks.

[DallasM5]

Status Service Center Date
Pickup: PROVIDENCE, RI 05/05
Current: PROVIDENCE, RI 05/05
ESTIMATED Delivery: FORT WORTH, TX 05/08

should have my car running by end of saturday.

[Crash]

End of Saturday is pretty optimistic, I hope it happens.

[DallasM5]

End of Saturday is pretty optimistic, I hope it happens.

no im making it happen, F the civic im in right now.

[DallasM5]

http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0647.jpg

replace or reuse?

im thinking reuse, looks fine imo.

[BlackSheep]

Your this far in.. Might as well replace it.

[Jetmech]

The clutch disk looks good from the picture, if the fly wheel has no chatter
marks and the pressure plate looks fine, I would reuse it. Any questions about the other two items and I would resurface the flywheel and replace the clutch assembly, JMHO.

[Jetmech]

Best of luck, looks like you have it under control:thumbsup2:

I just saw where you got another block, sorry about the post.

[Qship5]

Status Service Center Date
Pickup: PROVIDENCE, RI 05/05
Current: PROVIDENCE, RI 05/05
ESTIMATED Delivery: FORT WORTH, TX 05/08

should have my car running by end of saturday.

Is this end of Saturday with a stock engine? I know you mentioned some serious mods earlier in the thread.

[RaceMX-M3]

Are you having the motor built with upgraded internals? Prepping for a supercharger?

[DallasM5]

Is this end of Saturday with a stock engine? I know you mentioned some serious mods earlier in the thread.

stock engine end of saturday, second motor wont be here for about 2-3 weeks. i havent given the shipment on that a green light yet. im going to take the cracked block to a shop and see if darton sleeves can fix it. if thats the case then ill pass the other motor and have mine sleeved which was going to be done anyway.

Are you having the motor built with upgraded internals? Prepping for a supercharger?

10psi boost


reusing the clutch since i plan on having another motor anyway.
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0647.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0653.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0657.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0659.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0662.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0665.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_0666.jpg

[Qship5]

Sounds like a good plan Raza. Best of luck with the engine install and eventual rebuild.

When you do the built engine, just make sure the rest of the car is up to the task. (Having owned an E39 M5 and had the privilege of driving the Dinan S3 of the same, I can honestly say the stock brakes won't cut it for the power you are talking.)

[DallasM5]

Sounds like a good plan Raza. Best of luck with the engine install and eventual rebuild.

When you do the built engine, just make sure the rest of the car is up to the task. (Having owned an E39 M5 and had the privilege of driving the Dinan S3 of the same, I can honestly say the stock brakes won't cut it for the power you are talking.)

screw the build, more pics of chick in avatar. :scared0016:

[DallasM5]

Dispatch 05/06 07:40 newburgh, ny

[Qship5]

screw the build, more pics of chick in avatar. :scared0016:

LOL, I need to make sure that three pointed star stays clean.:D BTW, that is Jaime Pressly in my avatar

[Crash]

My Friday trip got cancelled so I might have some free time Friday if you need an extra wrench turning.

[DallasM5]

My Friday trip got cancelled so I might have some free time Friday if you need an extra wrench turning.

you know im down for that, UPS says the motor will come in early friday. i just swung by BMW to get the tools to remove the flywheel and few little things i wanted to change on the new motor so now im patiently waiting...

swing by if you're free, second set of hands is pretty useful, hell even blake who doesn't know the difference between a Philips and flat head was great help! :laugh:

[TiptronicSoldier]

you know im down for that, UPS says the motor will come in early friday. i just swung by BMW to get the tools to remove the flywheel and few little things i wanted to change on the new motor so now im patiently waiting...

swing by if you're free, second set of hands is pretty useful, hell even blake who doesn't know the difference between a Philips and flat head was great help! :laugh:

LOL:laugh:

[DallasM5]

http://farm4.static.flickr.com/3412/3514113535_4ae3032e80_b.jpg

[Crash]

Is it in yet.

[DallasM5]

sir yes sir

just got that sucker in

the amount of cuss words that i dropped infront of my father left him in shock LOL!!!

[DallasM5]

http://farm4.static.flickr.com/3150/3516331093_f5c67591c5_b.jpg
http://farm4.static.flickr.com/3351/3516331673_ae9163b632_b.jpg
http://farm4.static.flickr.com/3635/3516332743_6c665bf151_b.jpg
http://farm4.static.flickr.com/3372/3517146724_00618111a6_b.jpg

[Blake]

hell even blake who doesn't know the difference between a Philips and flat head was great help! :laugh:

****head :p

[DallasM5]

****head :p

:hahaha:

[snowball]

:hahaha:

Raza, you are a funny man. Sometimes your descriptions of things blows one's mind. :hmmmm2:

We really like the pictures, keep them coming....and looks like you'll soon be done! :burnout:

[DallasM5]

http://i5.photobucket.com/albums/y174/Ridgefootball80/th_MVI_0714.jpg (http://s5.photobucket.com/albums/y174/Ridgefootball80/?action=view&current=MVI_0714.flv)

[Crash]

Contrats man. I'm seriously f'ckin impressed with your abilities.

[DallasM5]

so lets see

i blew the motor on the 25th, took about a week to break down the head to see the block was cracked. found the block was cracked so i ordered another motor from rhode island which was delivered to me at 5pm on friday may the 8th. i began work that night by transfering the engine mounts and little things over to the new motor. the real work began saturday and i finished sunday night at 11:59 PM which is when i posted this.

pretty damn impressive if i dont say so myself.

http://farm4.static.flickr.com/3584/3520472353_207ac3e7ee_b.jpg
http://farm4.static.flickr.com/3372/3520472889_8ac96ac9a9_b.jpg
http://farm4.static.flickr.com/3403/3521284132_bf4f84c802_b.jpg
http://farm4.static.flickr.com/3598/3520474119_1b24882168_b.jpg
http://farm4.static.flickr.com/3316/3520474659_c06ab90d8c_b.jpg
http://farm4.static.flickr.com/3327/3521286622_f3a5e34788_b.jpg

and im still not old enough to legally drink, and i guess im technically a teen still since im 19.

life goes by fast.

-R

[imaj]

I look forward to seeing you on "Americas Got Talent"! Nice work!

[DallasM5]

I look forward to seeing you on "Americas Got Talent"! Nice work!

its a hobby, im sure there are others who have done more significant things that go unnoticed.

[Crash]

So is it officially back on the road?

[DallasM5]

So is it officially back on the road?

not yet

im waiting on few pieces i broke during the ordeal i want to replace, and i have 1 code that sends the car into failsafe. i think i need to reset the throttle bodies along with the servomotor so my DME can use its settings and tune.

i could drive around with it but i wouldnt have 400HP, more so 200hp in the failsafe mode and limited to 2500rpm.

[snowball]

I like the posts in the E39 M5 section of m5board - there is even a video of Raza starting it up. The diehard DIY E39 M5 guys are quite impressed! M5Board Thread (http://www.m5board.com/vbulletin/e39-m5-e52-z8-discussion/136558-bmw-s62-repair-rebuild.html):thumbsup2:

Here is a copy of the video link: Engine runs! (http://i5.photobucket.com/player.swf?file=http://vid5.photobucket.com/albums/y174/Ridgefootball80/MVI_0714.flv)

[DallasM5]

Raza, you are a funny man. Sometimes your descriptions of things blows one's mind. :hmmmm2:

We really like the pictures, keep them coming....and looks like you'll soon be done! :burnout:

what do you mean my description of things?

I like the posts in the E39 M5 section of m5board - there is even a video of Raza starting it up. The diehard DIY E39 M5 guys are quite impressed! M5Board Thread (http://www.m5board.com/vbulletin/e39-m5-e52-z8-discussion/136558-bmw-s62-repair-rebuild.html):thumbsup2:

Here is a copy of the video link: Engine runs! (http://i5.photobucket.com/player.swf?file=http://vid5.photobucket.com/albums/y174/Ridgefootball80/MVI_0714.flv)

thanks Gerald!



this is the only code i had during my install and its enough to make the car into failsafe mode. here's what the GT1 says.

107 electric throttle: self test
recorded as 1th fault in fault memory

note:
check connecting leads to servomotor

type of fault at 4th occurrence fault, specified-/actual-value comparison

(OBDII code: P1637)

the fault is currently present
detected 4 times


any ideas?

[DallasM5]

i give up

i cant figure out what that 1 damn code is even after running every test in the gt1.

[SyN]

good job honestly raza, pretty impressive.

[SyN]

and that engine looks super clean almost new.

[DallasM5]

good job honestly raza, pretty impressive.

thanks cody

off to BOD thursday and then out to virginia to pickup my other M5 lol :thumbsup2:

[SyN]

Other M5??? lol.

[DallasM5]

Other M5??? lol.

yes sir :D

[RaceMX-M3]

Raza, bravo brother. :thumbsup2: Very impressive work. I'm usually the one getting accolades for working on my car.. I think you just bested me. Look forward to seeing your car at our meet soon.

[RaceMX-M3]

Raza, about the faults related to throttle and limp mode..

There is a program that must be run for the throttles to "learn" correct open/close positions. Not sure if that was what you were referencing in your prior posts. If you don't have the software/hardware to run the programming this *might* be part of the issue. When I installed my VFE supercharger the throttle actuator arms were (barely) hitting the clamps on the intake boots and causing the car to go into limp mode. One of the techs at BMW of Dallas troubleshooted and fixed this for me. I would suggest making sure all of the mechanism/moving arms that control the throttle bodies are not obstructed in any way and have the BMW throttle position program executed through the OBD2 port. Hope this helps.

[DallasM5]

Raza, about the faults related to throttle and limp mode..

There is a program that must be run for the throttles to "learn" correct open/close positions. Not sure if that was what you were referencing in your prior posts. If you don't have the software/hardware to run the programming this *might* be part of the issue. When I installed my VFE supercharger the throttle actuator arms were (barely) hitting the clamps on the intake boots and causing the car to go into limp mode. One of the techs at BMW of Dallas troubleshooted and fixed this for me. I would suggest making sure all of the mechanism/moving arms that control the throttle bodies are not obstructed in any way and have the BMW throttle position program executed through the OBD2 port. Hope this helps.

do you know if the program is run on SSS, GT1 dis 52 or 44?

i have the coding software, just need to know which software to look in. could you hae the guy who did yours get in touch with me so i could speak to him pertaining to this matter. shoot me a pm if you dont have my cell, i think i gave it to you before.

[RaceMX-M3]

do you know if the program is run on SSS, GT1 dis 52 or 44?

i have the coding software, just need to know which software to look in. could you hae the guy who did yours get in touch with me so i could speak to him pertaining to this matter. shoot me a pm if you dont have my cell, i think i gave it to you before.

PM sent.

[DallasM5]

replied and ill keep you posted once i speak to him tomorrow.

[DallasM5]

oh ****!!! whered my car go!!!!!

http://farm3.static.flickr.com/2443/3529575757_75ccc86f2d_b.jpg

[RaceMX-M3]

oh ****!!! whered my car go!!!!!

http://farm3.static.flickr.com/2443/3529575757_75ccc86f2d_b.jpg

Hopefully it's running? drove itself down the street. :dontknow:

[DallasM5]

Hopefully it's running? drove itself down the street. :dontknow:

2nd gear pulls with a powershift inti third is the sh't!

:burnout:

[DallasM5]

i got the car running right and the starter is getting stuck now, what a kick in the balls lol...

[Qship5]

I have no doubt you'll beat it into submission Raza!

[SyN]

its like one thing after another lol

[DallasM5]

I have no doubt you'll beat it into submission Raza!

i cracked my whip and told her to listen to daddy!

Completion
http://farm4.static.flickr.com/3312/3532735206_d1430c7bf7_b.jpg
http://farm3.static.flickr.com/2107/3532719152_08e01b1311_b.jpg
http://farm3.static.flickr.com/2413/3532719404_51c3b3c788_b.jpg
http://farm3.static.flickr.com/2230/3531903177_64873b85ea_b.jpg
http://farm4.static.flickr.com/3642/3531904131_8af8cdaf96_b.jpg

http://www.youtube.com/watch?v=cQBB7vwaQBU

[Qship5]

Congrats Raza! This has to be one of the best DIY threads ever posted on the club forum. You are the man!:adore:

[RaceMX-M3]

Raza what ended up being the prob with the throttle?

[DallasM5]

Raza what ended up being the prob with the throttle?

wiring gremlin, plug #5 wasnt getting power to the harness. unplugged it and plugged it back in and all was well, the starter was a gremlin too, unplugged it and plugged it back in. everything works as it should now.


http://www.youtube.com/watch?v=cQBB7vwaQBU&feature=channel_page
http://www.youtube.com/watch?v=pOHqosUA0HY&feature=channel_page
http://www.youtube.com/watch?v=li5QwYiAWiU&feature=channel_page

[Qship5]

Don't you just hate those kind of issues? Glad it was an easy fix.

[snowball]

And he did this completely without BMW TIS and only online thing he looked up was the torque values for the pressure plate and clutch..........."winged everything else"......

Raw talent, or luck - I think some of both! Add a little smarts to that too (both kinds!). :thumbsup2:

[Crash]

Congrats man. Well done.

[SyN]

I'm sorry but LOL at video #1.... SPEEDBUMP!!!

[DallasM5]

I'm sorry but LOL at video #1.... SPEEDBUMP!!!

its not a speed bump!!!!!

the area raises like half an inch over there for drainage so it seems like a speed bump.

im sorry my car is so uber fast that it wants to take off like a rocket ship! :D



thanks for the compliments guys!

[Fubar]

Hell of a project. I would have a coffee can full of screws and be wondering what was going to fall off first.

[DallasM5]

And he did this completely without BMW TIS and only online thing he looked up was the torque values for the pressure plate and clutch..........."winged everything else"......

Raw talent, or luck - I think some of both! Add a little smarts to that too (both kinds!). :thumbsup2:


thanks gerald!!!

heres another one of my projects haha

http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_2986.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_2889-1.jpg
http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_2962-1.jpg
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http://i5.photobucket.com/albums/y174/Ridgefootball80/IMG_3458.jpg?t=1242452021
http://i5.photobucket.com/albums/y174/Ridgefootball80/sigmaterial.jpg?t=1242452292

[RaceMX-M3]

http://i246.photobucket.com/albums/gg86/M3bmwdrvr/DSCN0783.jpg
http://i246.photobucket.com/albums/gg86/M3bmwdrvr/DSCN0784.jpg
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http://i246.photobucket.com/albums/gg86/M3bmwdrvr/DSCN0786.jpg
http://i246.photobucket.com/albums/gg86/M3bmwdrvr/DSCN0787.jpg
http://i246.photobucket.com/albums/gg86/M3bmwdrvr/DSCN0788.jpg
http://i246.photobucket.com/albums/gg86/M3bmwdrvr/DSCN0789.jpg
http://i246.photobucket.com/albums/gg86/M3bmwdrvr/yzvc02-1.jpg

[Blake]

looks fun, and dangerous, which is also fun

[TiptronicSoldier]

http://pic50.picturetrail.com:80/VOL479/2235383/4368778/89428735.jpg

As far as I ever got my bike taken apart

[SyN]

its not a speed bump!!!!!

the area raises like half an inch over there for drainage so it seems like a speed bump.

im sorry my car is so uber fast that it wants to take off like a rocket ship! :D



thanks for the compliments guys!

lol, when you car goes over it, it almost looks like its about to bottom out but doesn't.... new M5 yet?

[DallasM5]

lol, when you car goes over it, it almost looks like its about to bottom out but doesn't.... new M5 yet?

nah i noticed it too after i saw the video.

i was going to leave friday to pickup the M, but my summer classes started friday so i couldnt go. i went ahead and had the car shipped. its suppose to be picked up mon-wed so ill see it whenever it gets here.

[AlexT]

Wow. You got balls. I'll look you up if my M ever need an engine swap. Of course, that's when I call for a "forced upgrade." A Dinan race version of the S62 would be awesome.

[mbowdo20]

Gratz man, glad to see you got it going again!