Jump to content

Mazz

Members
  • Content count

    77
  • Joined

  • Last visited

  • Feedback

    0%

Everything posted by Mazz

  1. always weird when you start a wip, it is infact a new chapter, of life, of car culture, of way of living. this is just my new way of wasting money in nonsense. last month I've bought my new car, paid waay to much for it because I went there already convinced that it was going to be mine, no matter what. I know estate v8 manuals are rarer than most of the cars I see every day, and this will make sense very soon. bs aside, this is the reason why I'm going to be completely broke in the next years e34 540i touring with a getrag 560, all factory, as far as i know this is one of the famous (?) 63 rhd produced. She's BH15015 for the vin number geeks out there This thing is my first car in the UK, therefore first one with steering on the wrong side, and first beamer, which means I have no experience on rwd bitches, and more importantly, first car that I bought myself. My ex money pit was a 94 civic eg6, if you're not into hondas is the first thing you can buy when you start every Gran Turismo career. mine looked like this I realised I needed a rwd car when I put my brother's e87 diesel into a wall trying to be an idiot, with success, and I've always been a fan of estate cars. I knew I was going to get a BMW, there's pretty much nothing else out there part from mercs which are all autos, not for me, I was pretty much sure that it would have been an e46 touring, maybe a 330d. I've read about these e34 touring and all the cool features they have, first of all the EPIC twin sunroof, and the split tailgate just like my old civic, self leveling suspensions, good engines and the fact that most parts are interchangeble with even more modern stuff. my dream was to build a touring with an m70, 6 speed and 520i badge at the back, but it takes years and lots af skills that I'll probably never have, so when I saw this 540 for sale among a jungle of auto 525s i knew that it had that "little more" and I made it mine. Neglected, probably abused and maybe even crashed, this car represents my idea of perfect vehicle: big, estate, rear wheel drive, good/big engine, manual gearbox, tough look, old style, massive sunroof. It's the only car that ticks all the boxes. and is nice to look at too, score ! When i brought it home I was very daunted: all by myself, no idea what this thing was going to do, I didn't test drive it because the dude wouldn't let me without insurance, and so the first ever drive was when the car was already mine. 146miles, Wolverhampton to South London.. here we go ! ...and it made it ! surprisingly this thing just ate miles and road, and brought my scared ass back home, champ ! very first thing, get it up on a ramp at work to check how bad the conditions really are: ...very, that's all I can say ! the described "surface rust" on the bodywork just meant that the guy never had it on a ramp. There is serios rust on the sills that have already started flaking, and I still have to check the inside of the front wings. It has had regular mots in different places, given the fact that all the numerous owners lived all over the country, so with the last one done last october I would assume that it won't fail again, but it needs to be sorted, one day or the other. on the bodywork it is actually just surface or slight bubbling, I can sort that myself, but stuff underneath, that will need someone that knows what to do... I've already "booked" someone suitable at work. so that's on the list. I've thrown in a set of plugs just for peace of mind, original ngks, I think they are bkr6ek. all the rest it's just a lot of neglecting and owners that cared more about looks and engine noise that actual car health. first saturday off (I used to work every other saturday before I had this car)I tried a first jet wash on the underside, so that I can really work out what is leaking and what is just dirty, or maybe just make my life a little bit easier when I'll have to crawl underneath to fix something ! car on axlestands in the wash bay, courtains around to protect valuable stuff, and look at all the grime that came out ! it's not even half of what's underneath that thing !! but then, sorry, I had to ditch those ridiculous angel eyes and HID that came with the car. I apologise in advance to HID people or angel eyes supporters, but I got to the point when I was driving at night with no lights on just because I was embarassed of those horrible things, and they were a complete mess held up with cable ties and electrical tape, they had to go. Got a set of original smileys for 100 pounds, and started working for the very first time on my new car. then I also tackled the completely loose exhaust by fitting two missing rubber hangers to the middle section and two clamps with some exhaust paste to actually connect it to the rear section, what a mess! It now leaks from the manifolds, which is a massive bonus, but at least is 50% functional. I then tried to regas the A/c, but had to stop half way through the process because I ran out of time and nobody was going to wait for a crappy bmw to finish regas, and so, next week, hopefully! this is the new look, with bonus cracked main beam next on the list was a compression check. you think m60, you think nikasil coating, so fingers crossed here we go. it did fine, 155psi average with a low of 135 and high of 170, I think i'm all right, I may actually be lucky with one of the latest alusil coated engines, still to check. wich me luck. then two weeks of stop because I was busy driving to the uk the very car that made me thinking about this in the first place, queuing at dunkirk and the last job so far, drive belts. the bentley manual says you have to take off the fan. obviously mine wouldn't play, I've taken them off anyway. and here we are. in the meantime I've changed the bonnet and bootlid struts, so those huge metal bastards don't break my neck everytime. in the future there is a full service with A/c regas, rust on chassis, sunroof, suspension, brakes, rust on bodywork, electrics, diff overhaul, oil leaks, thermostat... is a long list. the ridiculous shnitzer badge at the back will soon go, together with the side stripes. the number plate would have been fine 10 years ago when I was 15, not now. I'm still not sure wether to remore the 540 badge or keep it. I'm a fan of the clean look, but this is one of the few badges worth keeping. we'll see. and no M stuff, i should die first. I hope you've enjoyed it, saturday more misery still to come !
  2. Mazz

    '94 540i Touring 6spd - The Money Pit!

    Hi @Piper the car is still in the same garage pictured above, and I'm still using the Clio that in the meantime has been totally converted to Cup suspension and drove almost 20k miles in a year ! That would be impossible in the BMW, with the money I earn atm. Funny enough, I'm phoning different insurance companies today to find out how much could cost me to put the BM back on the road. Still needs the sills welded and outer panel replacing, and I'm halfway through repainting the replacement double sunroof cassette that was white. The exhaust also has to be put right but that's a couple of hours welding and should be done. I put two continentals at the back to ditch the useless nankangs, and professionally cleaned and balanced the fuel injectors. She does get started every few weeks, but really she's just been sleeping. Not to go anywhere though, this is my car, and still my favorite.
  3. Mazz

    '94 540i Touring 6spd - The Money Pit!

    This must have been a looong and "empty year" for the old barge. After all that work, she was put away in a garage and only came out last week for a cheeky run round the block to make sure nothing was seized. (and she clocked 145k miles a few minutes after that..) i purchased a little run around to have fun with, and I'm trying my best to get a little more out of each payslip, so that I can finalize the work on this car, and finally drive it. I'm worried that the engine may have some compression issues, as It still struggled to fire up when warm. if that will be the case, I don't know what my next move could me. i'm not getting rid of her, I said it !
  4. Mazz

    Avus E34 540/6 Touring restoration

    I saw that advert too. what a nice looking car, I've been following this thread for a long time and it has been a good source of info and inspiration to finish my own 540iT/6.
  5. Mazz

    E34 520i Touring Daily Project

    Good work Adam, makes me feel bad about my car that's been sleeping in a garage for months now ! Speaking of brakes, from a 540 touring owner, I'd say they could be a good upgrade for a car with a smaller engine like yours , specially if you can get your hands on a touring that has vented rear discs. Good luck
  6. Mazz

    '94 540i Touring 6spd - The Money Pit!

    I hope so bud, sometimes I wonder if I'll ever finish all this mess !
  7. Mazz

    '94 540i Touring 6spd - The Money Pit!

    A couple of pointless little fixes in the past weeks. First, I replaced the intake manifold mounting spacers; I somehow lost the originals while cleaning the manifold at work and only realized it months later when I was slapping it back on the engine. I ended up using regular washers underneath the nuts just to fire the engine up but later on I managed to order a genuine set from Cotswolds at a great price, like half of what it would have costed on eBay, go genuine! All then properly torqued, happy intake. --- I then put my attention to the cam covers, they looked pretty miserable after years of service and oil leaks, time to restore them I went for a dark grey wrinkle finish. I thought it was going to be way lighter than what it actually is, kinda like the original color, but I'm glad it's darker, unusual but still very subtle imho. I discovered halfway in the process of sandblasting the cam covers that the f*****g things are magnesium! Pain in the ass to strip down even using an aquablaster (can't imagine how hard could be without one), also weird material to paint on, I had to lay a thick layer of enamel primer to cover all the pitting and little caves on the surface, a real challenge. I'm usually pretty good at painting cam covers in wrinkle but each color has his own reaction times and look. This is a very light wrinkle, usually it's thicker than that, but I'm used to black and red. After all this the car fired up after two months and runs good. I think I have to have a look at all the exhaust manifolds nuts to make sure they're all right, I can hear a slight blow at idle. I have a new drive belt tensioner to put in next, then swap the sunroof, still a long way..
  8. Mazz

    '94 540i Touring 6spd - The Money Pit!

    I'll write down a simple list of things that I've done to the car so far, maybe I'll put it in first page so I can update it as I go. Engine: -Oil pump job (all the bolts back in, torqued down to spec) -valley pan gasket, genuine BMW -coolant crosspipe gaskets (acquablasted crosspipe) -water pump, new orings -BMW thermostat housing -Bosch knock sensors x4 -exhaust manifold gaskets x4 (blasted manifolds, painted silver vht) -new exhaust donut gaskets x4 -intake manifold gaskets x4 -cleaned intake manifold, hex bolts all round -cleaned throttle body and ASC tb -genuine PCV valve, new orings for the transfer pipe -cleaned ICV -alternator voltage regulator, new brushes -rebuilt starter motor -replaced engine mounts -new ancillaries belts -timing chain tensioner -new a/c condenser -new a/c receiver dryer Routine maintenance: -NGK BKR6EK spark plugs -Shell Helix HX7 engine oil -BMW oil filter -BMW air filter -BMW fuel filters Brakes: -WezMoto steel braided lines all round, new copper lines on trailing arms -Shell super dot4 fluid Exterior: -installed genuine headlights -Thule aeroprofil roof bars when purchased the car had some work done to it, some of the stuff remains on the car today -AC Schnitzer Type 2 wheels, 17x8.5, made by Ronal, set of five. -AC Schnitzer 3 spoke leather steering wheel -Straight through exhaust center section with 2.5in decat pipes -Remus Ac Schnitzer backbox -AC Schnitzer shock absorbers all round -deleted SLS rear suspension -Unknown lowering springs -3.15 210mm LSD -Alko tow hitch, helps when strangers rearend you without notice. -banging stereo, one of the best bits ! i think that's it !
  9. Mazz

    '94 540i Touring 6spd - The Money Pit!

    I haven't actually, do you think it could have anything to do with the unstable idle ? At first I thought it was the MAF sensor playing up, but disconnecting it upsets the idle even more, that means that it is working.
  10. Mazz

    '94 540i Touring 6spd - The Money Pit!

    The car finally runs folks. The new starter solenoid turned out to be the wrong one, it was given as a direct replacement from woodauto, but it clearly wasn't. Swapped that over, cleaned the spark plugs, charged the battery and after a whole lot of cranking the beast finally came back to life ! I'm in love with it again! There's still something to tweak, the idle is still not so smooth, the exhaust blows slightly at the backbox, I still need to rebuild the handbrake and sunroof and the sills have to be sorted. Once that's done I'll look into some staggered style 5s and she'll be done ! ACS Type 2 up for swaps people!
  11. Mazz

    '94 540i Touring 6spd - The Money Pit!

    Never changed the Maf, will look into one but I have to get the car running first. It cranks really slow, I thought it just was a bad battery bud does the same with a brand new one, it's probably the wiring on alternator or starter. You're right on the orings but I just didn't check my parts, I thought all the new bits had prima with them and I later found out they didn't
  12. Mazz

    '94 540i Touring 6spd - The Money Pit!

    The Nikasil thing doesn't bother me, I'm just curious is this car has had a replacement block or not, just to add to the history I have. By the looks of it no, but the long engine number may reveal something. Anyway, here's a little summary on how the weekend went down. As I said I had the precious help of a friend that flew from home, and that is also very handy with cars and greasy stuff, with his help everything seemed doable, still not Toyota easy, but doable. We started Saturday at 8 am, with the exhaust manifolds I blasted them, tested them for leaks with the smoke machine, and then a lick of silver vht paint. All to go on with new gaskets, new copper nuts and copper paste on the studs Looking good First use for the torque wrench, 22nm on this one. Next-> The hero that helped me with the broken bolts made a comeback to finish the job, one last stud to drill out for good Stud extractor didn't work, time to drill and tap Cleaned all the metal shavings and used the die grinder with a scotch brite disc to clean the gasket surface Same for the water pump, while I had the tool New gasket, genuine And new bolts 15nm and onto the next bit Let's tAke a brake from the engine and focus on getting cool, which in this time of the year doesn't sound fun but in the middle of august I'll be hopefully driving this thing, I want the a/c to work! New condenser with new nuts and grommets, old fan still going strong In place Last minute addition, new r134a receiver dryer I reused all the orings, they didn't leak and the new parts didn't come with any. They're easy to change, not to worry. Back to the v8, the refurbed starter in place And the alternator with the cooling duct Speaking of cooling, the new water pump is next Cross pipe first, looks new but it isn't, new gaskets and bolts, 10nm Then the cooling lines with new orings (ripped one during fitting, I realized once all the engine was back together, and had to redo all the intake, fun) In the picture you can se the new knock sensors (£150, ouch) Forgot to take a picture of the new pump in place, sorry. And then a whole lot of greasy stuff like refitting the intake with the almost new pcv valve, new bolts all round, new gaskets and orings as well as new hose clamps. Radiator and fan back on, the repaired exhaust on with new gaskets and new stainless bolts, I had to rush because it was getting dark. Plugged all the harness back in, hope its right.. Here's a shot of the engine back together It's all done ! No more parts laying around, it's all it and plugged in. But is it running ? no I wired something upside down or forgot a ground somewhere, will look into it, it was late on Sunday night when we finished. Lots of lessons learned, and quite excited to hear the sound of a clean running engine. Coming soon !
  13. Mazz

    '94 540i Touring 6spd - The Money Pit!

    Hi folks, I'm not going to get into the details of today, will do that when all the work is done. I have a question though: I found this number while replacing the valley pan gasket (yes, success..) With the engine assembled it would be right underneath the throttle body and the water pump, completely invisible. I know from the casting number that mine should be a nikasil block, but how do I decode this other number I found? Any help would be much appreciated, Thanks !
  14. Mazz

    '94 540i Touring 6spd - The Money Pit!

    If all goes to plan, this weekend may be a big step forward. I've got a friend coming all the way from Italy to help me fire up my car again, a good dose of motivation (aka beer), and lots of hope. Let's not speak too soon though. In the meantime I decided to get the valley pan off after the debacle with the broken bolt; the whole point of what I'm doing is to do stuff right, and leaving a broken bolt deep inside the engine is not the way to go. The disassemble gave me the joy of three more snapped bolts, one almost flush with the gasket surface, a real pain. After days of struggling with a blow torch I managed to borrow the oxy acetylene bottles and jet from work and did the job, right! Only the last of the 4 snapped bolts remained in the block, we are going to drill it out no problem. All the parts are gathering for this weekend rush to get this car running again. I shall not forget anything! But, I will, if I know me .. Wish me luck !
  15. Mazz

    '94 540i Touring 6spd - The Money Pit!

    I'll look into that thanks ! And then think about getting a manifold with velocity stacks or not..
  16. Mazz

    '94 540i Touring 6spd - The Money Pit!

    My rusty pile already has a 3.15 diff, also 2inch straight trough pipes and Remus back box. The inlet manifold hasn't got velocity stacks, which surprised me.
  17. Mazz

    '94 540i Touring 6spd - The Money Pit!

    I'm no engineer mate so I have no idea on how they flow. Sure they don't look like they are any good for performance but I can imagine the struggle of engineering an exhaust system for a mass produced saloon car with a big ass engine in a smallish bay. Again, they look damn well made, that's for sure.
  18. Mazz

    '94 540i Touring 6spd - The Money Pit!

    The stock manifolds are an utter disaster if you ask me. Not only they are completely different design from side to side, but they are restrictive as hell! Mind you, there isn't a lot of space to play with, specially in the e34. With that said they are a really nice piece, they look really strong and after I blasted them, they are literally as new. OE engineers are not stupid, the engine is made to work with them, but I'd love to get some decent tubular ones. If there were any.
  19. Mazz

    '94 540i Touring 6spd - The Money Pit!

    Well, I'm glad to finally say that I'm done dismantling my car, and from now on will only be bolting new/uprated/working bits to it, to hopefully make it work in time for this summer. I have absolutely no idea about half of the bolts I took off; where they go or come from and where to plug all the engine harness, but I'll get there, hopefully. Today I've completed the stripping down, taking off both the air conditioning condenser and receiver dryer once I was there. I've already got a spanking new condenser to go on, the dryer is on order. Then I was going to remove the famous valley pan gasket, or coolant jacket gasket, the last of the job that "I might as well do". Well, the gasket never leaked, and when this happened: I sort of hoped that it will continue like this, as I'm not changing it! Torqued all back, live in peace. The real reassemble will start soon, I'm fixing the broken decat pipe and I've finished the exhaust manifolds that are now my pride and joy. From looking like this Via this To the final result (two still bare) It's amazing how stainless steel is... well, stainless. Came up exactly like new after aqua blasting, so i decided to paint it silver to give it justice. The rest of the exhaust will be black with of course the chrome tip. All to go on pretty soon together with the rest of the renewed bits.
  20. Mazz

    E34 520i Touring Daily Project

    Just read the whole of this. Top work ! I personally approve the period correct dealer number plates, it's something I've always wanted to do. Apart from the lights choice everything else is spot on, keep it going
  21. Mazz

    '94 540i Touring 6spd - The Money Pit!

    Yours is a great source of inspiration !
  22. Mazz

    '94 540i Touring 6spd - The Money Pit!

    Hello boys, The manifolds are finally out. Took about 4 weeks of figuring, trying, cursing and then trying harder but I somehow won. The job was made harder by whoever worked on this car before me, I hope they have some serious but not fatal (hey I'm a human!) and fucking scary accident of some sort. The original problem was the one or more manifolds were leaking, pretty obvious when the car was cold, but still earable when cruising. I found out two weeks a ago that one of the pass. side bank manifold nuts was loose, but I couldnt live with myself just tighten it, and so I got the whole 4 manifolds out for acqua blasting, painting and re sealing. The job itself is pretty hard, there is no space at all and you need to have the starter out at least which I had, and tiny hands which I don't. The knurled BMW bolts between manifolds and down pipes were long gone, instead whoever put the decat pipes on, replaced them with generic long bolts, only cutting two of them, leaving a whole lot of useless thread sticking out. Thanks buddy (scary accident in your future as well I predict)! Borrowed a £800 snap on impact and a nice £200 ratchet with 6 point sockets and I got the bolts out, only broken two while trying with hand tools of my own, once again the right tools do help. With the bolts out the rest of the exhaust would not disconnect from the manifolds, seized. Greeeeat. I had to remote the rear bumper to access the back box hangers in order to remove them and jiggle the whole exhaust using its wheight to get the down pipes to release, a breeze of a job I later disconnected the muffler from the center pipes so that I could move them individually. That's an uber rare and expensive AC branded Remus backbox, one of many rare and expensive parts that i found bolted to this otherwise very unloved and rusty car. Jiggling the downpipes worked, manifolds are out, at a price though The weld on the right decaf pipe had let go, almost completely broken off, another problem I really didn't need. Here are the fuckers What a rubbish design, they say E39 M5 ones are the same, and they flow good enough for 400hp! Btw, I had most of the nuts off already, I got the last ones off today (jacking up the engine) and out they came, what an absolute pain! Working on this car, specially on the exhaust, has been utterly painful. It is not mechanic friendly, everything is really difficult to get to, plastic stuff breaks really easy and finding space to put your hands on stuff is a true challenge. I thought to myself multiple times to just give up and sell the whole thing for somebody else to put back together. But I'm just afraid it'll end up broken up or scrapped. I love this car, I'm just not sure whether I'll be able to put it back on the road or not, I almost completely forgot how to put everything back together, and working on a gravel driveway is not fun. By the way, here's the rest of the day in a couple of pics: Cleaned up behind the rear bumper, no car wash has ever been in there, also the bumper itself had a ton of grit in it, cleaned that as well. Useless stuff that helps relaxing. Let's see if I'm brave enough to tackle the reassembling process !
  23. Mazz

    '94 540i Touring 6spd - The Money Pit!

    Another quick update on the renewal of all the components I took off the engine. The alternator has had a thorough clean, I didn't disassemble it because it charges fine, but I did put a new set of brushes and a voltage regulator just to be on the safe side and Kept the old one as a spare. The thing was filthy, now at least you can handle it without contracting Ebola or something Then is the turn of the starter motor. Now, my car a slow start problem, it would fire up fine when cold, but had trouble kicking over when it was hot. I've read that this could be due to a bad starter solenoid that would basically heat and expand because of the normal operation of the engine. I couldn't really test this theory but since I will be putting a new battery anyways, I just thought I'd rebuild my starter while it was out of the car. Interesting experience, lots of help by a mate that is an awesome auto electrician and has done hundreds of the damn things. Here's the unit completely disassembled Note the aluminium part of the casing after aqua blasting And then the whole thing back together again. A new solenoid (that needed re drilling and tapping to fit my unit), new set of brushes and holders, a good renewal of the contacts on the motor, greased all the gears and a lack of black paint I've already scratched it. Once I had the aqua blaster warm and ready, I cleaned all the aluminium bits from the engine and they came up mint, including the starter heat shield This last one may be a little bit useless but hey, they look good !! A new starter or alternator would have costed probably around 80 quid each for aftermarket units. In my experience oem components are really good and can be serviced to last twice as long or even more. I spent less money and learned something, plus I know what's in those things now. that's a win win. The car in the meantime has been jet washed underneath several times. I got a new genuine valley pan gasket from Cotswolds, will be putting that in soon. The last bits to come off the engine are the exhaust manifolds... and god they're a pain !!!
  24. Mazz

    '94 540i Touring 6spd - The Money Pit!

    Just found a better shot, I'm still confident it won't be too bad
  25. Mazz

    '94 540i Touring 6spd - The Money Pit!

    Hahaha yeah reality check still in progress !! I know this car is a pile, nothing that a body shop can't fix though. As I said, I'm going to concentrate on the mechanicals, once that's done I'll worry about the sills. Thanks for stopping by
×