135i Turbo rebuild - my winter project

[mccandless]

Sub-frame is out. it wasn't as bad as i expected. I just took my time and slowly maneuvered it around the steering rack. It defiantly helps that the sub-frame is aluminium and isn't as heavy as it looks.

Everything is pretty messy thanks to the leaking gasket in the oil filter housing. I'm going to have to clean everything before i start reassembly.

[mccandless]

It's been a while since I've made any progress because i was stuck on some rusted nuts on the downpipes With a lot of work and heat i was still only able to get one of the 4 nuts off. So screw it... I decided to take to whole damn exhaust off to get enough access to cut off the other 3 bolts. Not easy working with jackstands, but i got it done. Phew, that's enough for today...

[mccandless]

Lots of rusty bolts left to come out yet, hope none of them break. This is what Canadian winter does to cars. I don't know the full history of the car, but i know it has been used for at least 3 winters (not by me).

[mccandless]

Didn't get the turbos out today, but i made some good progress. Some of the bolts are pretty hard to get at, patience is key.

The water pump and thermostat were replaced at a garage 2 years ago by the previous owner. When I started to remove it I noticed it was already loose. One of the two bolts in the thermostat was missing and one of the three bolts in the pump was only finger tight. Somebody rushed that job and didn't re-check the torques.

[MN.BIMMER]

Really cool to watch these build/teardown threads get updated vs scrolling through an older thread that's no longer updated. Very interested to watch your rebuild progress and maybe learn a thing or two.

[mccandless]

OLD TURBO'S ARE OUT!!!

[SixBanger]

Originally Posted by mccandless

OLD TURBO'S ARE OUT!!!

Wow alot of work. So, what did you use as a guide? Can you tell me what tools you used? sockets and everything?

[mccandless]

Originally Posted by SixBanger

Wow alot of work. So, what did you use as a guide? Can you tell me what tools you used? sockets and everything?

I did a lot of research before i started, but this youtube video was the most helpful thing i found.
https://www.youtube.com/watch?v=jWhgKqlTHGY

No real specialized tools, just make sure you have a Torx Bit set and an E Torx socket set. Everything is metric (the way it should be). I also found that a mini ratchet set is very helpful getting at the screws around the tubros. You'll also have to replace every aluminum bolt you remove, so be prepared to spend like $400 just on nuts, bolts and gaskets.

[mccandless]

New turbos are in along with the oil lines. I'll do the coolant lines tomorrow.
I also did the oil pan gasket this week.

[1and1]

Nice!
Any chance of pics with the oil pan off?

[mccandless]

Originally Posted by 1and1

Nice!
Any chance of pics with the oil pan off?

I didn't bother with a picture. There's not much to see. The crank and all the interesting bits are covered by an oil splash plate.

[dtla1]

Definitely get a new belt!!

Maybe also a new tensioner pully since you have the fan out of the way and it's not too much money/tends to go bad sooner or later. Also, buy from FCP Euro! Lowest prices around (Lifetime warranty if you want to say return your used oil and get new oil [people apparently do that], or just regular replacements), not sure how they are to Canada though.

[mccandless]

Coolant and air lines are all hooked up now. replaced over 20 gaskets so i'm really hoping none of the leak. There is defiantly an order to putting things back on.
Also, i got all new screws for the lines. They are not aluminum, so the don't need to be replaced. I just didn't want to put rusty screws back on the car. I added an older picture to see the difference.

• Remove the heat shields
• Install Coolant drain lines in the block
• Put the oil supply lines in the turbos before you install them
• Install rear turbo first then the front (Don't forget the vacuum lines and air inlets)
• Install the oil drain lines
• Put the coolant in supply lines in the turbos, but don't install the other end yet.
• slide the heat shields back behind the turbos. It take a little patients and the screws are a little difficult, but i managed. Make sure all the oil and coolant lines are tucked in behind the shields to protect them from the turbo heat.
• Next install the Air outlet pipe from the turbos to the inter-cooler.
• reinstall the water pump and thermostat.
• Then finally install the coolant supply line hard pipe. I found out the hard way that if you install that too soon you won't be able to get the heat shields in or install the air outlet pipes

Tomorrow it's the down pipes.

[mccandless]

Installed the downpipes and exhaust today. It was a big job because i had to drop the whole exhaust because the downpipe bolts were rusted on. I ended up cutting off the downpipe bolts that were pressed in, so i had to get those removed and drilled out. I replaced it with some stainless steel hardware so hopefully that won't happen again.

Maybe tomorrow i'll be able to get the sub frame back in.

[mccandless]

Damn it!!!! i just realized that the engine mount has to go in before the downpipes.

I'll deal with that tomorrow

[mccandless]

The engine mount and downpipes are in. Installing the pipes a second time around the mount was a pain in the ass, specially since i'd already done it once.

[Issagoat]

Originally Posted by mccandless

The engine mount and downpipes are in. Installing the pipes a second time around the mount was a pain in the ass, specially since i'd already done it once.

I love the updates! Going to do a oil head gasket replacement soon and that seems hard enough can't believe what you've been going through, awesome job!

[mccandless]

I installed the subframe, engine mounts, and steering rack. The engine support in off No more banging my head on that stupid thing every time i walk around the car.

I'll assemble the rest of the front suspension tomorrow and maybe even the front bumper.

[mccandless]

Things are moving along quickly now. i got the front suspension, headlights, and front bumper installed today. a few more small things and the car should be back on it's wheels tomorrow.

Then i get to start on the top engine work

[1and1]

Awesome progress! Really happy to see you wrapping things up!

Be sure to get the front suspension under load, or compressed to normal ride height, before tightening the control arms....

[mccandless]

Originally Posted by 1and1

Awesome progress! Really happy to see you wrapping things up!

Be sure to get the front suspension under load, or compressed to normal ride height, before tightening the control arms....

Yup, i jacked up the wheels just enough so the car lifted off the jack stands before i tightened things up.

[mccandless]

The car is down off the jack stands and on it's wheels.

I got the new serpentine belt installed today. Also the oil filter housing and thermostat with the new filter. I started cleaning the valves, but it's a lot more work than i expected. I got 3 done before i ran out of cleaner (and energy).

I'll finish up the other valves tomorrow and start putting the air intake back together. I'm hoping to be able to start the car this weekend.