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The Story of the Crispy30

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    The Story of the Crispy30

    R3v,

    I'd like to share the (ongoing) story of my E30 as it's currently undergoing a rebuild due to an engine fire a couple of weeks ago.

    Some background: I just turned 20 and bought this Alpine White 1986 325es from my neighbor—the original owner—in November 2021. I had passed it everyday on my way too and from school and I always wanted it! The car was bone stock and in very rough shape as he wasn't a mechanically savvy person, so it was leaking from everywhere (and had been for some time). I was out of town when the purchase was made so I did extensive research, ordered tons and tons of parts, and spent 120+ hours over 10 days refreshing everything I could: I resealed most of the engine, replaced all mounts and bushings, upgraded to Bilstein B8s and H&R lowering springs to replace the old blown suspension and a gold tag E46 steering rack to replace the old leaky steering rack, and facelifted the car to late model plastic bumpers as the diving boards were in poor shape. The interior was in excellent condition because the car had always been parked in a carport facing away from the sun, meaning a crack-free dash! It was a factory sport interior and the PO had always had seat covers (which looked raggedy), but the leather sport seats underneath looked brand new! It's star feature is an old Alpine car phone that I think was installed in the early 90s! (Doesn't currently work but I have a plan for that ;) ) After christening it the Crusty30 (for hopefully obvious reasons), I shook it down by driving it around the neighborhood...just kidding, I road-tripped it 370 miles up north to Berkeley! All went well and besides a few non-critical electrical quirks I didn't get around to touching, the car worked fantastically well and I ended up driving to and from Berkeley a few more times in the following months.

    Cut to the weekend before the 4th of July this year: I had been daily driving the car to and from work (about 30 miles round trip) for a few weeks and loving it! I had just CLEANED cleaned it inside and out so it was looking fantastic and had just upgraded the sealed beam headlights to ellipsoids, which was a huge upgrade. Man, I love this car! I wanted a little more pep from the tired M20 but don't have the infrastructure for an engine swap, so I was looking around for 2.5L parts to 1.1/1.3 Motronic swap the car (thanks to the fantastic thread my kenika65!).

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    [This is how the car cleaned up, basically at it's prime (a few days before I installed the ellipsoids)]

    On the weekend of the 4th, I was on my way to watch an oval race at Irwindale Speedway as you do, and when I pulled up to a light a few blocks from my house, I heard a pop followed by smoke and passersby yelling at me to get out of the car. I shut the car off and jumped out, saw flames underneath, and my heart sank as I watched helplessly as my pride and joy burned. Very luckily, there were a ton of witnesses so 911 had already been called by the time I got out and there was a fire station literally one block away from the intersection so they were there within minutes. My hood release cable melted so they had to chop my hood off to put the fire out.

    Most everything plastic and rubber in the engine bay was torched but luckily none of the belts snapped or anything, so I was confident the motor was alright. I towed it home and began stripping it down, removing all the burnt stuff to get a better sense of what happened. The firemen had said something about a fuel leak and since the pop I heard sounded like it came from the trans tunnel, I assumed one of the soft lines down there popped and fuel got on the exhaust. They also recognized my car and were sad to see it under those circumstances, although they had fun with it (did I mention the car has a car phone?!).

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    [My hood being cut off (left) and the firefighter taking a pic with my car phone (middle) saying "hey guys, this is how he called 911!", the aftermath (right)]

    To my confusion, when I got under the car, all the fuel lines were intact (and in decent shape all things considered) because the fire was concentrated on the passenger side. Still confused, I decided to scrub down the engine bay to see where the deepest scorches were (remember how I mentioned the car was crusty? Yeah, a few days and half a dozen kitchen sponges later, the bay was clean). Come to find out, the A/C line that runs from the compressor up the passenger strut tower popped and it was refrigerant that had been burning! No idea how this happened, the A/C had never blown cold so I never had it on.

    Some of you may have seen the thread I posted after it happened looking for parts and thanks to many fruitful junkyard runs and a bunch of you guys, I have all the parts I need to rebuild and upgrade my M20B27 (and entire engine bay lol). I'll be posting updates as they happen to keep the story of this amazing car alive.

    Long live the Crispy30!
    Thanks for reading!
    Hugo
    Last edited by ASEHugo; 08-03-2022, 09:53 PM.

    #2
    Here are some more photos: after I removed the burnt stuffs (left), after I cleaned the engine bay (middle), and the culprit (right):
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      #3
      Bummer but glad to see a rebuild happening!

      Usually the cold start valve leaks fuel causing a fire on the passenger side.

      Coil brackets can tear landing on exhaust and grounding out ign power making things toasty there.

      I was up above it, Now I'm down in it ~ Entropy - A Build thread.
      @Zakspeed_US

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        #4
        Guess its time to swap! Could've been worse, but still a crusty situation
        Simon
        Current Cars:
        -1966 Lotus Elan
        -1986 Mercedes Benz 2.3-16
        -2006 Volkswagen Jetta TDI

        Make R3V Great Again -2020

        Comment


          #5
          Damn that’s crazy. The fireman was wild for the selfie but I do give them extra credit for the smooth hood cut.
          sigpic84 325e

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            #6
            Did your car have the "fuel cooling system"?
            Possible candidate for fire.



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              #7
              Originally posted by 808ETA View Post
              Damn that’s crazy. The fireman was wild for the selfie but I do give them extra credit for the smooth hood cut.
              He was really cool about the picture and made sure that I was okay with it but definitely on the wilder side LOL!
              The hood cut was pretty nice all things considered and looks a bit like those hood cuts showcar guys do to show off their bays. Small over cuts on the fenders but all fixable!

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                #8
                Originally posted by Panici View Post
                Possible, but I don’t think so. That line in the picture you sent looks like mine except for that module or valve or whatever in the bottom left, the side that enters the cabin. Was that a factory option or something? What cars came with it? What did it do…?

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                  #9
                  Originally posted by ASEHugo View Post

                  Possible, but I don’t think so. That line in the picture you sent looks like mine except for that module or valve or whatever in the bottom left, the side that enters the cabin. Was that a factory option or something? What cars came with it? What did it do…?
                  It was an exercise in over-engineering. They were using the AC system to cool the fuel before it hit the fuel rail.
                  Only existed on a limited number of cars, so I guess that makes it a rare option. I threw mine out

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                    #10
                    Hey R3v, it's been a while! I just recently realized I didn't post any updates! How could I...

                    We last left off with me showing my burnt engine bay the bird, but I have since rethought the source of the fire. I believe moatilliatta is correct in that the cold start injector was likely leaking, which started the fire, and the pop I heard wasn't the fire starting but rather the AC line popping due to the heat in that area.

                    A detail I didn't mention at the time was the day after, once I had time to recover, I put the car up on jack stands and turned the motor over by hand, to verify that any and all repairs attempts would be worth it and I wasn't in need of a replacement engine. It hit me how awesome of a resurrection this could turn out to be, so in my post-cleanup excitement, I clearcoated the engine bay to lock in the soot forever.
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                    ​Now it was time to gather parts and get to work! With the very gracious support of Robert Fisher and some very successful junkyard runs, I started by addressing the damage at the firewall.

                    I was very lucky the fuse box and chassis harness on the drivers side were functionally unscathed, but the battery ground hub on the passenger side did not fare as well. My car has the battery in the trunk and therefore has the longest and thickest ground cable I'd ever seen running through the firewall all the way back to the trunk. Since the engine bay side burned to a crisp, the whole cable needed to be replaced. This involved some light interior disassembly but was not bad overall.
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                    Last edited by ASEHugo; 10-16-2024, 01:46 PM.

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                      #11
                      2.7i time! Huge thank you to kenika65 for the exhaustive write-up. I'm the kind of person that prefers to measure 3,764 times and only cut twice, so being able to pore through that thread and determine every single part, gasket, bolt, etc. that I would need for my setup was very welcome. It all begins with an 885 cylinder head from an M20B25, so off to FB Marketplace we go, and I happened to find a very very nice example for only $200!

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                      Being a complete novice, I took the internets advice and brought the head to a shop to be pressure tested. My negligence in updating this thread is coming back to bite me now because although the head pressure tested well, I cant remember what the shop said about it's mating surface wear (how much its been decked). Also, due to the budget nature of this restoration, I did not have the head rebuilt or decked (as I understand it, the valves must be removed in order to get them sufficiently out of the way) but I'm pretty sure I had them check its flatness and it was within spec. Score!​​ I took a look at the old timing belt, which wasn't that old as I had replaced it about 7 months/~4,000 miles before, but thanks to FCP Euro's Lifetime Warranty, I decided to redo all the preventative maintenance I had done before as...preventative maintenance. The block behind the timing components was singed and gross so I cleaned that up and got to work removing the old, likely original cylinder head.
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                      Last edited by ASEHugo; 11-02-2024, 04:41 PM. Reason: Fixed some of the images

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                        #12
                        Neat idea with the clearcoat!
                        Glad the engine can be saved.

                        A point of clarification: That's a +12v power wire running back to the battery.
                        The entire chassis is used as a ground, there is no dedicated ground wire running front-to-back.

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                          #13
                          If you're still in there, replace that stamped cam gear and intermediate gear with the later sintered versions because they're both known to fail

                          IMO now is the perfect time to swap to the late model cooling setup as well.
                          Originally posted by priapism
                          My girl don't know shit, but she bakes a mean cupcake.
                          Originally posted by shameson
                          Usually it's best not to know how much money you have into your e30

                          Comment


                            #14
                            Originally posted by Panici View Post
                            Neat idea with the clearcoat!
                            Glad the engine can be saved.

                            A point of clarification: That's a +12v power wire running back to the battery.
                            The entire chassis is used as a ground, there is no dedicated ground wire running front-to-back.
                            I've messed around in the battery area so much I should know that lol but every time I see a large black cable coming from the battery my mind goes to ground (pun intended). Thanks for the clarification :)

                            Comment


                              #15
                              Originally posted by Northern View Post
                              If you're still in there, replace that stamped cam gear and intermediate gear with the later sintered versions because they're both known to fail

                              IMO now is the perfect time to swap to the late model cooling setup as well.
                              I should clarify that I'm catching this thread up on the progression of the rebuild, but yes, while I was in there I upgraded to a late model thermostat, radiator, and hoses but retained the early model water pump and expansion tank so I didn't need the crossover.

                              At this point, I was able to remove the brake booster which I'm going to safely assume has some internal damage, and was likely original to the car so due for replacement soon anyways.
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                              With the old head removed, I can take a look at the pistons, carbon galore. At the time I was doing this, I had no experience in engine disassembly so removing the head along was terrifying enough that I didn't clean the pistons much for fear of damage (if only I'd had this thread up to date at the time!).
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                              Here's the old head next to my shiny "new" 885 head, oof. Look at those rusty coolant passages!
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