Project: Stealth Bomber - The Build

[static667]

As many of you know from my teaser thread (http://www.zhpmafia.com/forums/showthread.php?7708-Project-Stealth-Bomber), I'm going to be swapping out my current engine, an M54B25 with 165,xxx and burnt piston rings, with an M54B30 that has 50,xxx miles.

Those who have been following my other thread will also know that the engine I received was not in the best of conditions. I was reminded by the guy who salvaged and shipped it to me that it is out of a wrecked car. I kinda got the short end of the deal but, you live and learn. I will be working with what I have and making the best of it.

So, the build begins....

http://farm9.staticflickr.com/8432/7847943700_e8a041f69b.jpg (http://www.flickr.com/photos/static667/7847943700/)
2012-08-22 19.44.30 (http://www.flickr.com/photos/static667/7847943700/) by static667 (http://www.flickr.com/people/static667/), on Flickr

That's her. That's what I will be working with.

So far, I've installed my spark plugs to close up the holes that go directly into the cylinders. This weekend, I'll probably be pulling off the oil pan and timing cover for some fun work. I plan on putting some loc-tite on my oil pump nut and possibly even "peening" the threads on it to keep the nut from ever coming off. While I'm behind the timing cover, I'll be replacing my stock timing chain tensioner with that of an M3. Time permitting, of course.

Stay tuned, kids! There is a lot more fun to be had here.

[static667]

So I started tooling around with the new engine the other day. Getting some of the maintenance stuff taken care of before the install. It didn't take long to hit a snag. I was in the process of removing the timing chain cover when I found a bolt that I couldn't get to. The E8 torx socket I have was too short to reach the center bolt.

http://img.tapatalk.com/aefc6511-bec2-4903.jpg

So, I had to order one.

Otherwise, everything under the valve cover looks ok.

http://img.tapatalk.com/aefc6511-bf38-7a5f.jpg

I also replaced the front crank oil seal. As you can see, the old one was leaking a bit.

http://img.tapatalk.com/aefc6511-bf86-e4b3.jpg

While I wait for the socket to show up, I'll be working on the oil pump nut. Stay tuned, kids. There are more chills and thrills to come...

[static667]

Further reservations....

[static667]

Another space for the build...

[static667]

You guessed it, more space.

[cakM3]

Looking forward to seeing your progress Kyle :thumbsup

Sorry to hear that you have some setbacks on your build though.....after it's all said and done...you will have an awesome car again...:)

[Hermes]

looking forward to seeing you get this done

[static667]

Me too. I hope to be getting some help from Mr. Hornung when it comes time for the swap.

[Hornung418]

In!

Horney...via TT.

[danewilson77]

Kyle...they have an improved OPN available, specifically designed to prevent it coming off. Excited for the build bro.


ZHP oil pump nut PN: 11417897238

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/1-1-1.jpg

Sent from Williamsburg, VA USA

[Hornung418]

Kyle...they have an improved OPN available, specifically designed to prevent it coming off. Excited for the build bro.

Sent from Williamsburg, VA USA

OPN will always find it's way off. The only way to secure it 100% from backing or shearing off is the Greg Vaio OPN modification. Other preventative measures include the S54 Tensioner and the ATI SuperDamper.

The stock Harmonic balancer only has a 5 year lifespan, so its something to consider changing if you haven't yet.

Anyways...super pumped to see the progress!

Horney...via TT.

[danewilson77]

OPN will always find it's way off. The only way to secure it 100% from backing or shearing off is the Greg Vaio OPN modification. Other preventative measures include the S54 Tensioner and the ATI SuperDamper.

The stock Harmonic balancer only has a 5 year lifespan, so its something to consider changing if you haven't yet.

Anyways...super pumped to see the progress!

Horney...via TT.

Disagree. I very infrequently hear of this happening.

Sent from Williamsburg, VA USA

[Audi 0000]

Looking forward to your progress, have fun with it.

[static667]

Updated the first reserved parking space.

Sent via Tapatalk 2 on my hacked Fascinate.

[SureShot434]

In for updates! Sorry to hear about all the setbacks! Good luck with the work, and can't wait to see more updates!!!!!

[static667]

Its about time I updated this. After taking my car off the road in October to install what I believed to be my new-to-me M54B30, I discovered that it was not the 3.0 which I had ordered and paid for. Of course I came to this conclusion after I had rebuilt the VANOS, fixed the oil pump nut, and replaced all of the gaskets. When I was in the final stages of the install, what tipped me off to the fact that I had the wrong engine was that my new DISA for the 3.0 did not fit, but my old one for the 2.5 would. I then went to find the information plate on the engine where the model and size would be stamped. The people that sent me the engine had seen fit to grind the info off in favor of a mirror smooth surface.

Needless to say, I was furious. After quite a bit of phone time with Saratoga Classics, The Parts Broker, and their supplier, Rhonda Auto Parts of Houston, Texas, I had another engine on the way. I then removed the engine that I assumed to be stolen from my car and filed a report with the sheriff's office. The deputy that took my report put me in contact with a DMV investigator who was able to raise the numbers from the ground down info plate. It came back as a salvaged engine from a 2003 325i sedan. Not the 2002 330Ci that I was assured that it was from.

When I received the replacement engine, I checked the plate on the engine and all the correct information was there. I then went into prepping this engine for install. When I went to rebuild the VANOS, I found the assembly full of what looked like chocolate milk. This beautiful mixture of oil and coolant was everywhere.
How did it get there? Warped head. How else?

I was on the phone with Juan at Rhonda auto parts the next day.

"There is nothing wrong with that engine, it was thoroughly tested." Juan promised me.

"Yeah fuckin' right" I thought.

I called up a mechanic friend of mine and borrowed his cylinder leak down tester.

Cylinders one and two came back with around 30% blow by. 3,4, and 5 were near 100%.

Yeah. Its a good one, Juan.

That one was sent back and a dispute was filed against the purchase.

My next engine was sourced from a salvage yard in St. Louis. When I received this one, it looked as if it had been sitting in a puddle for a month. When I pulled the intake off, this was confirmed by the water that poured out of it. All of the intake valves were well rusted. Credit issued, engine returned.

The fourth engine was sourced from a yard near Williamsburg, VA. Everything looked okay upon arrival. When I took the intake manifold, the inside of it was coated with thick, black goop. It looked exactly like the one I had removed, which had a bad case of burnt rings. Again with the leak down test. This one had greater than 90% blow by on all cylinders.

At this point, all this crap has gone beyond infuriating and right to funny. How many attempts will it take for me to get a useable engine? I'm ready to roll my car into a field and set it ablaze.

After hearing several suggestions to go with Norfolk Recycling, I did. Norfolk Recycling is one of the yards in the LKQ Corporation's network. I sourced my fifth engine from them.

My father and I drove up to their location in Chesapeake to pick up the engine. Everything looked good on initial inspection, I turned over my original block as the core, and then I was on my way home. When I got home, I pulled the intake and the plugs to check it out. Finally, everything looked okay.

The next day, Saturday, I prepped the engine. I set the oil pump nut, put on all new gaskets, swapped in a rebuilt VANOS, put on all new exhaust manifold studs, bolted on the exhaust manifold, and buttoned up everything else. Sunday, a complete install. By 21:00, I was rolling it back out of the shed. I then did the difficult part. Flashing the proper ZUSB to my DME (that's another story). Once I got it installed, it started right up. I even drove it to work the next day.

The continuing electrical issues will be covered in another post. Right now, lets just leave it at me finally getting my car back after three months of bullshit.

This long ass post brought to you by my thumbs, Tapatalk, an extended gym session, and a GS3.

[JupiterBMW]

Damn man... I somewhat followed your other thread, but this condensed version really puts it into perspective just how much BS you handled... You sir, are one patient guy. Hats off to you for that.

Good luck with the continued progress!

[Avetiso]

Awthum!

[kayger12]

Way to hand in there, man.

Sent from the last Next Best Thing via Tt4beta

[danewilson77]

Way to hand in there, man.

Sent from the last Next Best Thing via Tt4beta

+1

Kyle FTW!

[DasMechaniKer]

You are a trooper son! I think I would have had a few nuclear meltdowns if I were in your shoes.

[Johnmadd]

Glad its working out finally. Curious of what gremlins are lurking tho.

[Tnhl1989]

Congrats man. If there is anything I can do to help you got my information :)

[danewilson77]

Congrats man. If there is anything I can do to help you got my information :)

La Familia

:grouphug

[static667]

I need to pull my codes to see what is going on there. I still have to figure out where the problem is coming from. Too....many....wires....

[Tnhl1989]

I need to pull my codes to see what is going on there. I still have to figure out where the problem is coming from. Too....many....wires....

Well if you need a hand with that one :)

[SoCalZman]

You are a stronger man than I. I would probably just go straight to BMW and let them charge me 8 grand to put in a engine :-(


Sent from my iPad using Tapatalk HD

[johnrando]

Holy cow Kyle, way to hang in there.

[Oli77]

That sounds like hell! Have you had to pay for shipping these engines back?

[static667]

That sounds like hell! Have you had to pay for shipping these engines back?

Nope. I didn't have to pay any freight. The companies that sent them were at fault.

Sent from my yet to be hacked GS3.

[wertyu78]

Good job hanging in there. I just finished a rebuild on my b30. Rather simple motors these things are, somewhat.

[static667]

The Carbon Fiber Fairies have smiled upon me.
http://img.tapatalk.com/d/14/01/14/5ugu9yda.jpg
The arm rest will need some recoloring as the under sides are gray. Going to do some masking and spray bombing this weekend. I'll get the other bits installed and pics posted soon.

Sent from my TI-85 with Tapatalk 4

[derbo]

nice!

[kayger12]

:like

[cakM3]

Very nice Kyle!!! :thumbsup About time the carbon fiber fairies graced another car ;)


Sent from my iPad using Tapatalk HD

[johnrando]

Nice Kyle!

Sent from my DROID4 using Tapatalk 2

[static667]

Got the dash section of my CF trim installed. It may be a little bit before I get to the arm rest. Before and afters are attached.

Sent from my TI-85 with Tapatalk 4

[cakM3]

Oh yeah!!!!!
:like

[ELCID86]

Much better than the wood. Nicely done.

Though I bet you get fussed at about the setting of your dash vent scroll wheel--red dots...! :-0

[Johnmadd]

Looks great :thumbsup

[danewilson77]

Damn CF Fairies.

[johnrando]

Looks good! Where'd you get the CF?

[static667]

Looks good! Where'd you get the CF?

Charlie sent his CF fairies my way.

Sent from my TI-85 with Tapatalk 4

[cakM3]

Looks good!

Yeah Kyle....I agree with John here.....the new carbon fiber interior trim looks so much better in your car brother! :thumbsup

[wertyu78]

That trim.... a+


Sent from my iPhone

[wertyu78]

12076


Sent from my iPhone

[brettbimmer]

looks great Kyle! Keep up the good work. :thumbup

[static667]

http://img.tapatalk.com/d/14/03/26/durete3a.jpg

Tinted. 30% all around.

Sent from my TI-85 with Tapatalk 4

[danewilson77]

Boom! Just like that. Kyle shows up.

Sent from my SCH-I545 using Tapatalk

[328ioc]

http://img.tapatalk.com/d/14/03/26/durete3a.jpg

Tinted. 30% all around.

Sent from my TI-85 with Tapatalk 4

Excellent.

Sent from my SCH-I545 using Tapatalk

[HockeyGoon]

That car looks slick. Liquid metal.

[cakM3]

Lookin' good Kyle!!!


Sent from my iPad Mini using Tapatalk HD

[static667]

Boom! Just like that. Kyle shows up.

Sent from my SCH-I545 using Tapatalk

Hence the name Stealth Bomber....

Sent from my TI-85 with Tapatalk 4

[static667]

Thanks all. Still have lots to do. There are some items that need to be fixed and modified for the interior upgrade to be complete and next will be some 120 LED angel eyes.

Sent from my TI-85 with Tapatalk 4

[johnrando]

:like

[cakM3]

...next will be some 120 LED angel eyes.

Sent from my TI-85 with Tapatalk 4

Orion V4's :thumbsup