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From a broken e91 325i to a Moon Mileage 335d ...



Sir_Dave

ClioSport Trader
Thought i might as well detail this cars rebuild on here - i certainly put all the other cars, so makes sense!

Excuse me if its a bit of an info dump from a variety of different threads, but it saves me having to re-type everything (y)

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In effect, I did the usual, bought it on eBay, late at night, after a few glasses of wine. Naturally, I did this unseen, knowing full well that the car had a fairly obvious misfire and was using a bit of oil. Previous owner apparently couldn’t be bothered to fix it, so bought something else and plonked this on eBay.

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by Sir_Dave, on Flickr
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by Sir_Dave, on Flickr
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by Sir_Dave, on Flickr
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by Sir_Dave, on Flickr
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by Sir_Dave, on Flickr
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by Sir_Dave, on Flickr

Spec wise it was pretty loaded, manual and 3.0 petrol, so a rare old beast. I also knew that it was the same N53 engine as the 330i, just with a different inlet manifold and map. Fit both of them and my 218bhp 325i would be a 272bhp 330i straight away. A few hundred quid and i could LCI it as well - try and find an LCI 330i manual touring lol.

S313A Folding outside mirror
S459A Seat adjuster electric with memory
S470A Isofix system
S4AEA Armrest front retractable - now removed and put in the 335i
S418A Luggage compartment package
S609A Navigation System Professional CCC - also now in the 335i, so currently has S663A Radio System Professional
S633A Preparation mobile phone business
S677A Hifi system professional DSP (HK/Logic 7)
S6FLA USB audio interface
S507A PDC rear
S522A Xenon light
S524A Adaptive headlights
S5ACA Highbeam assistant
S761A Individual sunshade glazing

Being that N53’s are renown for their issues with coil packs, spark plugs & injectors, I took a punt on it. BMW had carried out a “quality enhancement” in 2011 and replaced all the injectors with Index 9, along with new coil packs & NGK spark plugs. Being that we were now 7 years later, I simply assumed they had failed again. What’s the worst that could happen … well …

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Cold start it starts instantly, runs ok for 5 seconds or so, then starts to jump about (really bad), with EML lights appearing & misfires on cylinders 5 & 6. After running for a couple of minutes, it struggles to start again, starter spins for quite a while.

Initial fault finding so far has resulted in:

Cyl 1: Unknown brand coil pack, NGK spark plug – smells of fuel.
Cyl 2: Delphi coil pack, NGK spark plug – smells of, & appears damp with fuel.
Cyl 3: Unknown brand coil pack, NGK spark plug – no fuel smell.
Cyl 4: Bosch coil pack, NGK spark plug – no fuel smell.
Cyl 5: Unknown brand coil pack, NGK spark plug – no fuel smell.
Cyl 6: Unknown brand coil pack, NGK spark plug – smell of fuel, very wet tip.

I cleaned all the plugs, re-inserted, then restarted the car, Cyl6 was instantly wet with fuel, all others were fine.
Then swopped the coil packs around, misfire stayed with Cyl5/6. Did the same with the spark plugs, misfire stayed on 5/6.
If I pull the oil cap, the idle stays the same, i.e. doesn’t get any/even worse.

Cylinders 6,5,4,3,2,1:
46014693384_3b79a93786_c.jpg
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by Sir_Dave, on Flickr

Cyl6 Spark Plug:
32864204058_3146980865_c.jpg
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by Sir_Dave, on Flickr

After buying a new 12mm adaptor, I then did a compression test (tested cold, all other plugs left in):

Cyl 1: Compression at 120
Cyl 2: Compression at 130.
Cyl 3: Compression at 130.
Cyl 4: Compression at 130.
Cyl 5: Compression at 110.
Cyl 6: Compression at 0.

At this point, after swearing a little, having read that a completely failed DI injection can occasionally cause compression pressure to bleed away giving a false reading, I bought a new Index 11 injector & de-coupler. Having removed the old one, I was faced this this, appears covered in white gunk?

Cyl6 Injector:
32864204258_fee2e5bfca_c.jpg
Untitled by Sir_Dave, on Flickr

New injector fitted and coded with INPA:
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by Sir_Dave, on Flickr

Re-started, still misfires. New compression test, this time done without any plugs in, all 155-165, barring cylinder 6 at 0.

Cylinder 5 sounded like this:

Cylinder 6 sounded like this:

When up to temperature, there is a decent amount of white smoke, this appears to have quite a nice smell to it. The previous owner said that since the misfire had started, it had started to burn a lot of oil :unsure:

Now, ive had a head gasket go on an e46 M3 between cylinders 5&6 a few years back, but from memory, it wasn’t at zero (just 5/6 comps were lower than all the others) and being that that’s a closed deck block, there was no coolant usage etc as the break was between the cylinders. The last time I saw zero compression was on my R53 Mini I after a bit of a valve broke off and prior to that failing completely, it also smoked blue like a chimney on cold start. The 325i has no blue smoke, which in my mind, would be the normal indicator of valve and/or piston ring issues?

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Re: the white smoke, having watched a billion N54 videos (they have the same type of injector), my initial hope was a failed injector, hence the purchase of a new Index 11. Normally, in this situation, i would replace all the injectors/coils/sparks as a matter of course, but with the injectors being so expensive, for the purposes of fault finding (the lack of compression) on CYL6 i have bought just the one.

Codes wise, ive got Carly & INPA. Not using the 2.023 loader for the MSD80 as per the Bimmerprofs websites suggestion however (no idea how to update it), so just on 1.001 for the time being. Carly/INPA are giiving me 29D1 & 29D2 for CYL 5 & 6 misfires, along with 29F3 for low pressure fuel sensor failure (the live data is also showing its stuck at 6500 hPa instead of 5k so assume its toast). Finally there is the (fairly standard on the N53) 29FE Nitric Oxide Catalyst aging.

Video of cold start. As you can see, the idle is generally ok initially, albeit rather tappy/loud, after which it starts to struggle massively:


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So after a bit more tinkering, i ruled out HG failure (bought a tester), rings seemed ok (wet compression test), then stuck an endoscope down the spark plug hole and the top of the piston looked ok. At which point, i was leaning towards valves, most likely inlet, due to the excess white smoke out the exhaust (probably unburnt fuel), but before i take off the head, it made sense to get a second opinion...

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Had a leakdown test done at BMS Surrey and the inlet valve on Cyl6 is stuck open slightly. Realistically, its quite difficult to tell whether the cause is bending/sticking as you can only see so much with a borescope, but he said that the top of the piston & cylinder walls seem to look ok. To speed up getting it back on the road, i've just bought a used cylinder head complete with cams/valves etc, so the idea is to simply swop them over, then strip the old head & sell the unused parts.

Currently trying to decide whether i can bothered to do it all myself, on the drive, in the cold & wet, or just pay them 12 hours labour to do it ...

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Weekend of the 30th/31st April, i made a start to the 325i's strip down ...

Starting point
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by Sir_Dave, on Flickr

Inlet manifold removed
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by Sir_Dave, on Flickr

Valve cover removed
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by Sir_Dave, on Flickr

Organised chaos
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by Sir_Dave, on Flickr

Turned the car over by hand a few times and by peering through the inlet opening, it does appear that the valve is still moving within its guide, but only to a certain point - meaning that the valve is still open say 5mm or so. Upon looking at the valve spring with the valve cover off, i "think" that i may have a broken spring; which would naturally stop the valve closing all way as its not being pulled all the way back out of the cylinder head. Its VERY difficult to see as its rather close to the bulkhead, but i think im going to remove the inlet cam (ordered the N53/54 timing tools today) and have a proper look before even considering pulling the head off.

With luck, itll be the valve spring and ill be able to swop it out with some overhead valve spring compressors. Normally you'd use compressed air to hold the valve up when doing the springs without taking the head off, but with their being no compression, i think, if im careful, i should be able to hold the valve up through the inlet opening with something to stop it dropping into the cylinder head. Otherwise i'll do the rope trick and feed that in through the spark plug hole, then bring the piston up to avoid the valve falling into the head - id rather not move the bottom end from TDC once its locked in place however. All in all, its a nice little project to keep me occupied through sunny days; useful to be learning on the job as well!!

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Well hello there broken valve spring:
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by Sir_Dave, on Flickr
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by Sir_Dave, on Flickr

The valve seems to move freely up & down the guide, closing nicely against the block when lifted all the way up, so ive purchased an overhead valve spring compressor, N54 cam chain tensioner tool, 5-25nm torque wrench and torque angle gauge - this weekend ill hopefully be able to remove the inlet cam, then swop the offending spring with one from another cylinder head i bought. Fingers crossed that'll be sorted then!! (y)
 

massivewangers

ClioSport Club Member
  Several
Be a nice result if you don't have to take the head off! Did you get a chance to check the towing weight?
 

Sir_Dave

ClioSport Trader
Be a nice result if you don't have to take the head off! Did you get a chance to check the towing weight?
Definately!!! Purely as the manifold and EGR bolts look like they'll be an utter pain to get to lol.

Any idea where i can find out the towing weight on the car? The e90 doesnt seemt to have a VIN plate anywhere like the old e46's ... just the number.

All i can find online is that it'll do 1700kgs gross.
 

massivewangers

ClioSport Club Member
  Several
Definately!!! Purely as the manifold and EGR bolts look like they'll be an utter pain to get to lol.

Any idea where i can find out the towing weight on the car? The e90 doesnt seemt to have a VIN plate anywhere like the old e46's ... just the number.

All i can find online is that it'll do 1700kgs gross.
Well that's weird. I looked on Parkers.co.uk and it said 1600kg ?

Is there a plate in one of the door shuts? That's where it is on the vauxpile
 

Sir_Dave

ClioSport Trader
Well that's weird. I looked on Parkers.co.uk and it said 1600kg ?
Is there a plate in one of the door shuts? That's where it is on the vauxpile
Ill have a look next time im out there messing with it (y)
Is the tired looking 5er wagon yours too ?
No lol, thats our neighbours, he bought an F10 530d to replace it. 3 YEARS AGO
Its sat there ever since. Turbo has gone iirc. Feel free to offer me peanuts £££'s wise to take it away!!
Every BMW in the south east is Dave's
I try :ROFLMAO:
 

Sir_Dave

ClioSport Trader
Cracking buy if that's the only real issue.
I think it is, still wont have been cheep to fix though, purely as ive had to buy soo many new tools :ROFLMAO:

So Friday was 325i day.

Valve cover back off, timing tool fitted:
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by Sir_Dave, on Flickr

Timing chain tensioner removed, vanos hubs removed from cams, top half over inlet cam cover removed:
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by Sir_Dave, on Flickr

Both cams & their ledges removed:
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by Sir_Dave, on Flickr
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by Sir_Dave, on Flickr

Hydraulic lifter removed & valve spring on cyl6 inlet side is confirmed as the issue:
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by Sir_Dave, on Flickr

At this point, i realised that my overhead valve spring compressor wouldnt fit. FFS. Hopefully the new one ive purchased will!!

If not, im going to simply keep trying new versions, there is literally no point going through the additional expense/hassle of taking the head off lol.
 

Sir_Dave

ClioSport Trader
So then, onto last weekend ...

More new tools arrived in the shape of a Laser 5258 overhead spring compressor - very cool piece of kit!!

Testing on the spare cylinder head i bought for "practice":
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by Sir_Dave, on Flickr

Then doing it on the cylinder head proper:
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by Sir_Dave, on Flickr

As you can probably see, in order to stop the valve dropping down into the cylinder, i held it very lightly with some padded plyers held together with masking tape. Whilst the compressor tool is fine for one-handed use, removing the valve spring keepers was definately a job that required two hands!!

One very broken valve spring :ROFLMAO:
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by Sir_Dave, on Flickr

All replaced and now i have a valve that seats correctly:
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by Sir_Dave, on Flickr

New rocker cover gasket & rocker cover back on again:
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by Sir_Dave, on Flickr

Nearly there:
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by Sir_Dave, on Flickr

Then time to get the jump leads out, crack upon a beer to calm my nerves and start it... ?

Success!!


Being that there isnt much info out there for the N53, i used the following N54 guide for the tear down (the Amercians love pulling engines apart far more than we do it would seem), as barring the turbos, it would seem they are very similar in terms of process: https://www.e90post.com/forums/showthread.php?t=1080990 along with the TIS N53 repair manuals: https://www.newtis.info/tisv2/a/en/e91-325i-tou/repair-manuals/11-engine/

The N53 specific tools purchased were as follows:

12mm spark plug socket
Gunson 12mm adapter kit
Laser 5153 Chain Tensioner Tool
N53 Timing Tool
Laser 5258 Valve Spring Compressor

I also needed to purchase a Teng 3892ag 5-25nm 3/8" Torque Wrench for lower torque nuts/bolts as my Halfords one only went down to 30nm.

Repair parts:

Low Pressure Fuel Sensor (13537614317)
Elring Rocker Cover Gasket (11127544368)
N53 Valve Spring (11347563459)
2 x N53 Camshaft Bolts (11367524954)

All in all, very happy!!

Now just need to get it taxed/insured, do the 2 x recalls at BMW, MOT it, take it to Le Mans (we need a 2nd estate car apparently), then decide what to do with it.

Did you check the towing weight yet? :ROFLMAO:
Nope lol. Nothing on the door sticker either. God only knows where the towing weight info is :unsure:
 

massivewangers

ClioSport Club Member
  Several
So then, onto last weekend ...

More new tools arrived in the shape of a Laser 5258 overhead spring compressor - very cool piece of kit!!

Testing on the spare cylinder head i bought for "practice":
View attachment 1416378
Untitled by Sir_Dave, on Flickr

Then doing it on the cylinder head proper:
View attachment 1416379
Untitled by Sir_Dave, on Flickr

As you can probably see, in order to stop the valve dropping down into the cylinder, i held it very lightly with some padded plyers held together with masking tape. Whilst the compressor tool is fine for one-handed use, removing the valve spring keepers was definately a job that required two hands!!

One very broken valve spring :ROFLMAO:
View attachment 1416380
Untitled by Sir_Dave, on Flickr

All replaced and now i have a valve that seats correctly:
View attachment 1416381
Untitled by Sir_Dave, on Flickr

New rocker cover gasket & rocker cover back on again:
View attachment 1416382
Untitled by Sir_Dave, on Flickr

Nearly there:
View attachment 1416383
Untitled by Sir_Dave, on Flickr

Then time to get the jump leads out, crack upon a beer to calm my nerves and start it... ?

Success!!


Being that there isnt much info out there for the N53, i used the following N54 guide for the tear down (the Amercians love pulling engines apart far more than we do it would seem), as barring the turbos, it would seem they are very similar in terms of process: https://www.e90post.com/forums/showthread.php?t=1080990 along with the TIS N53 repair manuals: https://www.newtis.info/tisv2/a/en/e91-325i-tou/repair-manuals/11-engine/

The N53 specific tools purchased were as follows:

12mm spark plug socket
Gunson 12mm adapter kit
Laser 5153 Chain Tensioner Tool
N53 Timing Tool
Laser 5258 Valve Spring Compressor

I also needed to purchase a Teng 3892ag 5-25nm 3/8" Torque Wrench for lower torque nuts/bolts as my Halfords one only went down to 30nm.

Repair parts:

Low Pressure Fuel Sensor (13537614317)
Elring Rocker Cover Gasket (11127544368)
N53 Valve Spring (11347563459)
2 x N53 Camshaft Bolts (11367524954)

All in all, very happy!!

Now just need to get it taxed/insured, do the 2 x recalls at BMW, MOT it, take it to Le Mans (we need a 2nd estate car apparently), then decide what to do with it.



Nope lol. Nothing on the door sticker either. God only knows where the towing weight info is :unsure:
It's not stated explicitly, you have to work it out. It's Gross Vehicle Weight minus Gross Train Weight. More details here: https://ntta.co.uk/law/law/towing-capacity
 

Sir_Dave

ClioSport Trader
Nothing too exciting, but gave it a quick clean yesterday (estates take way longer than convertibles & saloons though :ROFLMAO:), then coded the digital speedo and the mirrors so that they fold/unfold on the keyfob. After that it was insured/taxed so that i could go for a little drive. Everything seems to be working ok, but ill try and put a few more miles on it over the coming weeks to make sure all is well. The car is booked it into BMW for the heater & battery cable recallson June 6th, so no doubt they will find approx. £8 million pounds worth of things that need doing urgently ...

Scrubs up ok i think, although the wheels/lack of rear 12mm spacers do upset my eyes a tad - reverse rake is due to parts/tools, not cheapo lowz btw.

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Rojer

ClioSport Club Member
  Civic
Well done for getting it sorted! So nerve racking when you go for the first start!
 

mart.z.s

ClioSport Club Member
  Audi A3 2.0T Quattro
Glad it’s come out OK in the end! Looks really good after a clean! Blue is the one to get looking at this.
 

Christopher

ClioSport Club Member
Looks great now. They're a bigger car to wash than they look, I know how you feel there.

Get the LCI track sorted at the rear with some spacers and you're away. Bargain.
 

Sir_Dave

ClioSport Trader
More parts fitted over the weekend, mostly little bits that have been annoying me.

Both bonnet struts were knackered, so i picked up some new ones - although i forgot to take photos.

The tailgate ones were also a tad tired and no longer holding the boot off my head.

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by Sir_Dave, on Flickr

£30 on Amazon later and some OEM ones (Stabilus make them, BMW then put £60 BMW tax on them):
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by Sir_Dave, on Flickr

Get the LCI track sorted at the rear with some spacers and you're away. Bargain.
And as if by magic ... 12mm spacers now arrived & fitted to the rear.

Before & After
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by Sir_Dave, on Flickr
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Before & After
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by Sir_Dave, on Flickr
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Stupidly, i then forgot to take a photo of the whole car, but i did get one of it performing lifting duties at the local garden centre. Looks great i think.

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by Sir_Dave, on Flickr

Next job is (no laughing) to refit iDrive, ive managed to pick up a cheap dashboard, plus acquired a broken CIC nav off ebay (which ive now fixed), so that'll be going in it prior to Le Mans (hopefully with a combox if i can find one cheap enough) so we'll have better access to music etc. Also, hadnt realised before that its on run flats still. Oh my days they are hard :oops:
 

Rojer

ClioSport Club Member
  Civic
Can you fit the manifold and have it mapped please then i'll come and buy it, thanks.
 

Sir_Dave

ClioSport Trader
Can you fit the manifold and have it mapped please then i'll come and buy it, thanks.
Funny you should say that ...
After a few months of searching, this just popped up on Ebay in Lithuania. Naturally, i bought it straight away:

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by Sir_Dave, on Flickr
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by Sir_Dave, on Flickr
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by Sir_Dave, on Flickr

I'll still need to buy the DISA flap and work out how to make the 330i OEM map work on the 325i (it can be loaded on with WinKFP with some "binary modifications" apparently), but getting hold of the manifold is the difficult part really (y)
 

Sir_Dave

ClioSport Trader
Love this thing.

10th Le Mans in a row, car acted as a van, carrying literally ALL the stuff :ROFLMAO:
There's a fridge in there, plus a BBQ, in excess of 150 bottles of beer, enough food for 6 people for 5 days, plus all our camping gear!
To the roof all the way to the back of the front seats...
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by Sir_Dave, on Flickr

Acting as the beer chiller during the weekend. Not ideal as the battery was flat Monday morning :rolleyes:
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by Sir_Dave, on Flickr

Avec Le Roofbox
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Best Place Ever.
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Fully loaded, cruising at 80-85 it averaged just under 35mpg over 800 miles. Not bad for a 3.0 petrol.
 

Cribert

ClioSport Club Member
  Cup 172
Looking good mate. The touring is brilliant as a luggage loader.

Mine has new run flats all round (Michelin I believe) and I’ve found them ok. Is the ride noticeably better on standard tyres?
 

Cribert

ClioSport Club Member
  Cup 172
Also what spacers are you using? The rear wheels sit horribly on the pre facelift, need to rectify that
 

Sir_Dave

ClioSport Trader
Also what spacers are you using? The rear wheels sit horribly on the pre facelift, need to rectify that
I get the following from cmwheels off m3cutters, "forum10" will get you 10% off (y)
BMW Wheel Spacers
5x120 / 72.6
2 Pack
Silver Spacers
2x12mm Bimecc Spacers
Silver Bolts
Without Lock Bolts


In terms of tyres, ive got Hankook runflats on this and Michelin PS4's on the 335i - the ride quality is night & day!!
 

mart.z.s

ClioSport Club Member
  Audi A3 2.0T Quattro
What do you do with regards to a spare Dave? Or just have the foam if not on runflats?
 

alistairolsen

ClioSport Club Member
If he's anything like me, breakdown cover, and since the two punctures I've had on E90 were due to broken front springs, a spare (or runflats) wouldn't have helped anyway
 

Kev@KAM

ClioSport Trader
  Badass Toyota
When you going to move to the F series so I know what can be done on mine? ha ha
 

Sir_Dave

ClioSport Trader
ALL the camping gear you say...... ?
Well, most of it :p

When you going to move to the F series so I know what can be done on mine? ha ha
Not for ages lol, unless the 3.0 petrols get to sub £5k sooner than i think ...

In terms of the 325i updates. This just happened.
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by Sir_Dave, on Flickr

Semi-jokingly said i had too many e9*'s in a thread on PH, chap messaged me telling he wanted it, viewed it the next morning, took a deposit and its just driven off. Was handy in a way, i collected this yesterday ?

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Basically the bloke i bought the roofrack for Le Mans off texted me asking if i wanted it and well, i havent owned an M57 yet ... so, yeah, now i have.

Its a 2 owner '09 LCI 335d with Adaptive Xenons, Headbeam Assistant, CIC Nav, Split Front Armrest & Electric Folding Mirrors. Oh and:

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by Sir_Dave, on Flickr

:eek:

Next job for the 325i was to fit the manifold, remap it and go full LCI, but then, for a lot less £££'s it was sense to just buy a newer/quicker car in the first place!
 

mart.z.s

ClioSport Club Member
  Audi A3 2.0T Quattro
That didn’t hang around long at all! And neither did you ? looks smart in black.

I’m going to get myself on this PH thread you keep referring to as seems where most of the dealing seems to be!
 


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