Rob and Joost E12 528 type 1 ----> 535i

[Yoozt]

great, thanks! very helpfull, also for the central locking.

[Yoozt]

Well, here we are again, we've done a lot, but we're not much further than the last post, BUT we learned a lot and had some fun. so..

after we hooked up the engine, with a temporary fuelpump system (next to the car with jerrycan and loose wires) the engine wouldn't start..
The startmotor turned the engine over, but nothing, not even a hint..
We checked everything, fuel came out of the injectors, sparks out of the sparkplugs, but nothing..

We let someone else have a look at it, and he thought the engine didn't make enough pressure, no plops out of the exhaust manifold.
So we decided to take the head of the engine to see if the piston chambers or gasket were too worn down.



and the head:


these pieces came out:


luckily the damage on the head was inside the chamber and gasket area so we send it to a company to have it pressurised (is that how you say it) and shave the head.
by putting pressure on the head we found out the head was cracked... so, 'lucky" us, good thing we took the head of...

As you may have read in an earlier project post this is our second engine. The first one was almost finished when we cracked the head by turning the bolts of the intake manifold to tight..


We hoped that it was only the small heads of the bolt holes, but after testing this head at the revision company, this also turned out to be cracked..

so, we bought another head via internet, but, "lucky" for us the revision (tuning) company found out it was cracked too, so we didnt have to do a 3th test (extra costs)

Hard to see, but it has a dent and it is cracked all the way to the sparkplug hole.

Luckily we got our money back (after getting really angry) and the tuning company called us and said that a M30B35 had arrived at their shop and we could use the head!
so a couple of days later our 4TH! head finally was finished!
with freshly shaved valves + valveholes, rubbers etc.




Another thing with the engine was the lower part, it was pretty worn, luckily the other engine looked a lot better


In the end we decided to also overhaul the lower part of the engine, the engine holes were good enough to hone/shave (how do you call it) just a little bit so we could re-use the old pistons.

it fitted perfectly in the back of my car:


cleaned up the pistons




and put them into a ultrasone bath



we replaced the crankshaft bearings, the crankshaft was polished, new pistonrings and bearings





with a feeler we checked if the clearance of the pistonring was good


putting in the rings and assemble!



old bearings


then we build up the engine again, new timing chain, sprockets, slide rails, seals, gaskets etc



for the oilpan of the E12 to fit we used the oilpump of the E12 + the sprocket and chain, we didn't renew them, bit of a shame, but they were in good condition


head mounted


With our own made tool (old vibration damper + long metal strip) we tightened the Collar nut of the crankshaft. It took us 3 tries to get it to 440Nm...
First time the tool broke at the welding joint, second time the whole damper broke! :


some engine porn:




so the engine that was in the car came from a E24, so the engine mounts both fited, but the new engine came from a E34, so the right mount needed to be shifted, so we made our own mount:





and then! the engine was back in! 2 months after we took of the head to see what was going on...


and YES! the engine started, still no exhaust, but here's a link
https://youtu.be/kgIoEWamOZk

As some of you may notice it isn't running smoothly on all cylinders...
We took the whole engine apart and fixed and renewed everything! well, almost everything.

We didn't clean the injectors.. so that must be the problem.

Tomorrow we will take them out and let them get tested, cleaned and tested again
AND THAT MUST DO IT GODDA*$# IT!

So we'll see you next time!

ps. when the engine runs smoothly we will start mounting the front side panels, the front, the grill, the lights etc and make it look more like a BMW again!

[uwbuurman]

lovely work, but what a hassle with those heads and worn out blocks. People must know what they sell, so the sellers of that second block is a fcuker all day long. The seller of the thirth head also. Man....

But the engine is superb now! Congrats!

[Yoozt]

lovely work, but what a hassle with those heads and worn out blocks. People must know what they sell, so the sellers of that second block is a fcuker all day long. The seller of the thirth head also. Man....

But the engine is superb now! Congrats!

yeah you're right... you never know... good thing is now we learned a lot about building a whole engine! and its as good as new!

[Mihajlo]

there is nothing like revving freshly build engine without piping....

[323baur]

Very good job. Still an impressive machine.
After the holidays we meet up!

[Jeroen]

Pfew what a load of work, including too many setbacks... bad luck and utter idiots selling you cr@p just as well.

But a beautiful result... almost there!

[RobK]

Our new rule is never buy an engine if you don't see and hear it running... And one positive note is that we learned so much!!!

[Jeroen]

Never trust a seller of car parts, or cars for that matter hehehe

Btw thanks for the extensive report on all your hard work!

[madridcab]

Impressive work, Any further progress?

[uwbuurman]

Congrats on the birthday, Joost!!