M62tu engine work

[Jean]

I had the pleasure of removing an M62tu + 6speed out of my brothers 03 m-sport car as he have possibly overheated it. Dealer tests confirmed there are exhaust gasses present in the cooling system when engine is HOT, compression and leak down tests are fine and no coolant is present in cylinders. Further testing required removal of engine/heads for diagnostics, which would cost to the tune of $5k+.

Anyways, with some help from good friends I pulled the exhaust/tranny and then finally m62tu out of the engine bay for further diag.

I'll post some pictures later today, and as I go through the process.

Heads are going to a local machine shop first, if the problem isn't found then block is going to follow.

This shop is local and has good rep here in town - http://www.cascarmachineshop.com/for_you.html

Vac also does some work on these (http://www.vacmotorsports.com/catalo...ng-service.htm) , but I don't have unlimited time/$ so going with someone local instead.

[Jean]

For the most part it was not hard. Remove the coolang system, disconnect engine harness from the dme/relay box. Disconnect the PS lines and remove the AC compressor.

I removed the exhaust first, then driveshaft and 6speed came out. I didn't want to risk pulling engine and 6speed as one unit NOR did I want to drop the subframe, these aren't like 2002/e30s...lots more junk everywhere.

So, once the tranny was removed (will get new clutch/short shifter, etc). Engine stated to come out, but it was too tight on the driver side, so I ended up removing the exhaust manifold on one side to shift the engine over and then it came out.

Now some pictures -











Exhaust is huge, but no problems removing it.



Drain oils/coolant, start removing more things



coolant system stuff



ps lines , this way you don't have to deal with the cooler but you could just remove the ps pump from the engine instead as well.



compressor , pretty straight forward but a tight fit



these cars have a CDV in line with slave cyl, to "delay" the clutch work... some like it , some done. look it up



removed oil pan, made a mess on the floor. but no plastic or bolts in the pan = good



don't need to remove all heater lines, just two that go to/from the engine.

[Jean]

No here is where it gets wierd. For some reason, there is OIL on top of the DME one one of the plugs..so something pushed the oil UP the engine harness into the relay/dme box. WTF right?!





6speed about to come out, nothing unsual here...removed oil first.







then comes the engine





engine bay



work area, thanks Charlie!!!

[Jean]

More tonight/tomorrow.

[slammin.e28]

Sub'd.

[Jean]

Got some more progress done today in 3 hours before it started to get hot.

Clutch is almost worn after about 130k. Guides have some grooves, but less than expected, will be replaced anyways.

Harness, manifold, and accessories are off. Just need to free up the chain from the intake cams, got the reverse thread bolts off but not sure yet how the chain is supposed to come off the vanos unit etc before taking the heads off.

Will post more pics later today.

[325ix]

That is exhaust is odd looking. Are those little offshoots for quieting rasp and sound?

[Jean]

Some more progress from today -

Engine harness removed, best to just do it with the fuel rail still attached to not deal with the fuel injector clips due to little room.

Once it's removed, it's time to remove the intake manifold and unclip the evap line under it.

Removal of the belt hardware is needed to remove the pump, and then the rear coolant 'neck' for both heads.

Passenger side engine mount comes off with the oil dipstick/tube....

Down to figuring out how the vanos / sprocket is to be removed and then heads are off.







back side / clutch





passenger mount / oil tube



front of the engine, pump removal





upper timing come off, vanos unit ..







parts removed lol

[Jean]

Got the heads removed today, no obvious areas of failure....I am taking the heads off to a good machine shop.

V8s deff. have lots of parts, and I'll have to source/borrow cam timing tools for sure when it goes back together.

[Jean]

Pictures -







oil separator was on it's last legs...added to the list of parts to order..



vanos unit, i believe they have rebuild kits for these so might as well since it's out.



head





block





both heads removed, was getting too hot so I haven't removed the front lower cover yet..

[Jean]

Heads -

[Jean]

Engine is on the stand, need to take the front cover/oil pan off and get all these parts cleaned before putting everything back together after it's checked out.






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Heads currently at the machine shop for cleaning/testing and re-surface job. Was told they pressure tested fine and not cracked, and so far it's just the head gaskets. The 32 lifters were cleaned/cams were polished. Heads/front covers are getting resurfaced next.

I've taken the pan(s) and the front cover today, couldn't get the flywheel off as I couldn't find a deep thin wall torx socket.

I've taken this bolt off before with the engine in the car, and should have done the same now before pullin the engine. It took some heating of the hub and then a good size breaker bar to get it off.... PITA but it's off.



to stop the crank / flywheel form rotating I placed a piece of wood on top of one of the cylinders as I've seen this done before. Placing a pin between the flywheel and upper pan didn't work, tried that first.



pans and front main cover off, will get hot tanked along with some other parts



oil pump was not missing any bolts, everything was there.



some pics of the forged crank/bottom end







front chain hardware, after 8 years and 120k+ miles these were very hard/brittle and breaking. The chain was holding some of the stuff together, once the chain was removed you could easily tell these were due.

[Jean]

Hmm, are the pictures not showing anymore?! I uploaded them to photobucket.

Anyways, heads have been decked as they were both 0.006 warped. Block appears to be fine, I got a set of 0.0015+ filler gauges today and even the smallest one does not fit under a straight edge.

Had to get a special tool to get the flywheel off, not sure of the flywheel condition at this time. May need/want to replace with with the clutch at the same time. Clutch will have to be replaced.

Replacing rod bearings, leaving crank/pistons alone as compression/leak down numbers were good.

Starting to make a list of parts to order, so far over 1k in just gaskets/bolts/timing chain/guide components. OH, and still need to do something about both Vanos units to make sure they are 100% good while they are out.

This is w/o clutch/flywheel/engine/tranny mounts. Damn.

[Holland]

All the pics look fine. Hot damn though, that's a lot of work.

[dirty30]

Starting to make a list of parts to order, so far over 1k in just gaskets/bolts/timing chain/guide components. OH, and still need to do something about both Vanos units to make sure they are 100% good while they are out.

This is w/o clutch/flywheel/engine/tranny mounts. Damn.

It adds up fast!