(Yet another) M42 top end refresh and engine reseal (mid-2021)

[jsnppp]

Looking good. Should ask an admin to move it from here into the project forum

You are right, I didn't think of that. Thanks, I'll reach out..

Jason

[econti]

Looking good. Should ask an admin to move it from here into the project forum

[jsnppp]

Current state!

Condenser in place (not fixed). Wiring re-wrapped, some metal bits on the nose (behind the radiator) touched up with paint, ABS wires replaced, brake sensor done...





An interior shot too. It's all there, justwrapping up..

[jsnppp]

Does it run?

Not yet! Radiator needs to be finalized, fluids added and an overall sanity check that it's all tight then we start it..

Very very close.

[econti]

Does it run?

[jsnppp]

Fan installed, belt installed, spark plug wires and coil packs installed, throttle cable in place.

Daughter finished the headlight buckets, they turned out very nice.

Tightened the steering rack, and found that one front brake pad wasn't installed correctly, the spring was backwards.

Interior wise, a lot of scrabbling to ensure all lights work and all dashboard functionality is present. Took a while to figure it all out. I'm glad the 6 button OBC works!

I'm going back and adding oetiker clamps where appropriate.

We also wrapped the wire loom that runs in front of the radiator.

Am now going in and rebuilding the brake ABS wiring...

I'll add photos to this post shortly..

[jsnppp]

We are making progress! Paint is on the frame behind the radiator and so once that is complete we can finish the coolant.

Then need to torque the power steering components, install the primary alt - fan - waterpump belt, fill with oil (we will back fill it) and start thinking about starting it.

Photos coming. I've been updating the first page to reflect how things really unfolded.

[bmwman91]

Good progress there. Yeah, the mess under the intake is not just an eyesore, it makes installation and removal of the upper intake manifold an even bigger pain in the ass! Ideally you won't need to pull it off again for along time.

[jsnppp]

I'd say we are 85% there..





We are happy with the progress. It's been slow but these take time.

The intake was a bit trickier than I thought. We found we had a few missing nuts (not sure where they are hiding in the garage, but it's been months so no surprise. I had to order from FCP). Intake was challenging because the parts seemed to need to be installed in a certain order. We found that putting the hoses on the throttle body and then installing the rest helped.

* Coolant hoses and plastic runner under intake, coolant temp sensors
* Intake manifold w/ fuel rail
* Plenum w/o throttle body
* Electrical rail, plug in to sensors, etc.
* Install all intake hoses as best you can, trial and error to make sure it all aligned properly
* Install throttle body with hoses

There are always a few backwards and forwards, for instance:



I didn't realize the sensor wouldn't fit behind the bracket when we installed the bracket months ago. Off it came! I didn't like doing this b/c of danger of "breaking the seal" on the lower timing chain cover. Should be ok, but note for others that are doing this. (I'll add to front page).

Next up - paint the body that surrounds the radiator (had chips), install radiator, install condenser, coolant hoses, fan, belts, mass flow meter, IAC, add oil, prime engine.

Then maybe even start it! The goal is to start it by end of holiday break (New Years).

[jsnppp]

I don't have anything against the original hose setup, just that its complex and more expensive to refresh than to do the tidy up

I debated on reducing the hoses. In the end I did not. Was a bit more money with probably no return on it, but thats ok.

Made a ton of progress, more photos coming up!

[jsnppp]

FCP Euro has free shipping over $50..just load up with even more parts! Lol

Me too! I swear they are making their weekly sales quota from me alone.

[Gkwan]

FCP Euro has free shipping over $50..just load up with even more parts! Lol

I found that I am missing three hoses so I'll put that order in. One more check to make sure that I'm not needing something else.. I love paying shipping on parts, don't you?

[econti]

I don't have anything against the original hose setup, just that its complex and more expensive to refresh than to do the tidy up

[jsnppp]

I have photos but haven't uploaded.. Also need to update the workflow on page one.

Just got back from holiday travel and worked on the "mess under the intake" hoses last night. Had to lay them all out on the ground to see if I could figure out what we needed. Really complicated set of hoses.

I know that simplification is a common path but I'm going to make it all work as stock. You all can shake your head collectively :-)

I found that I am missing three hoses so I'll put that order in. One more check to make sure that I'm not needing something else.. I love paying shipping on parts, don't you?

I have all the interior lights in and so can reinstall the cluster and onboard computer, etc..

[jsnppp]

UPDATE.

Good progress. Installed the head, oil filter housing, water pump.

It took longer than we thought. For some reason things got in the way of another but it all worked out at the end.

Torquing the head bolts was a bit of a knuckle biter! Glueing the profile gasket and then making it all line up was also a knucklebiter. It's all a knucklebiter, especially when dropping tools while trying to line up everything etc. Couldn't have done it without my partner in crime (it will be her car, she's excited).

Now comes the easier bits. Hopefully speeds up now. I've updated the main page too.

Photos coming soon!