E60: New Engine finally running!

Changed the injector seals last Sunday and gave the ports another good clean. The mist has stopped, but it still did not want to fire. There is fuel to the injectors and the timing is spot on, so this could only mean 2 things - something electronic isn't working properly, or the entire DDE module has fallen out of sync with the engine...

I don't even want to know what the latter option entails, so carried on swapping sensors on the new engine for those that worked on my old one. I found the crank-sensor was completely covered in dirty oil, in fact the whole slot was filled with it. Engine sensors are funny things and I can see how the oil could stop it from seeing the notch on the flywheel, but it doesn't explain why the engine would not turn over well using a can of Easy-Start. Either way, with the crank-sensor from my original lump in place it fired up straight away! Result.

[Video is with EGR-pipe disconnected and no air-filter / muffler fitted.]

• PAS-pump sounds like it's dying - extreme whine / groan when the wheel is turned - and is now the only thing keeping her off the road. Will try bleeding tomorrow and maybe fresh fluid, but failing that the pump could have packed in or, worse, I've damaged some of the piping / rack while lifting the engine in.
• Rear rubber exhaust-hanger missing. TIS says to remove the screws holding the hanger-bracket, not remove the rubber. I cut mine off to hastily get the exhaust down and will have to buy and annoyingly fit a new one.
• Front exhaust vibration-damper simply will not fit. When fitted to the exhaust, the eyelets on the two connecting-rods are way off the studs on the gearbox-bracket. The left-right rod is only about 5mm out, but the front-rear rod is miles off. I will have to remove the rear and centre brackets and try to relocate the exhaust a bit.

Other than that, no iDrive messages, no engine-management light, no 'Increased Emissions', no leaks, no mist and no funny noises. The gearbox and clutch are working fine and the car is desperate to be driven. Curse that power-steering fault!

E60: Engine Swap Week - Day 7

• Remove inlet-manifold, rail, injectors and rocker cover.
• Improve fit of fuel-rail return pipe.
• Clean injectors.
• Clean out injector ports in head.
• Fit original rocker-cover.
• Adjust injectors to fit collars tightly.
• Look for fuel in rail and rail-pressure when cranking.

The only thing I didn't do today was swap my crank-sensor over. I figured the automatic models have a different flywheel so would have a different sensor, but the two transmissions share the same sensor [exact same part no.] so the one that's on should work.

The banjo on the fuel-rail return hose needed refitting, as the jubilee-clip was now fouling the inlet-manifold. It was a bugger to find a way to refit it and give enough gap - the manifold is still fouling slightly.

I fitted my original rocker-cover because the new one has a crack round the MAF-sensor housing, obviously where the donor car had it's bump. The injector collars were fitting a bit loosely in the new rocker-cover too and are a bit tighter now. My original cam-sensor is back on too, which I doubt will make a difference, but can't hurt.

• Re-attempt start!

NO! The engine is turning ok and there is fuel-pressure. Sadly, there is now a lot of diesel-mist shooting up past the injectors, as in the vid below. Ah well, nothing ever goes smoothly.

E60: Engine Swap Week - Day 6

• Replace snapped T-piece on injector leak-off pipes.
• Torque up crank-pulley and HP-pump.
• Refit drive-belts.
• Refit radiators / coolers.
• Refit headlights and crash bar.
• Refit slam-panel and grilles / ducts.
• Plumb cooling, A/C and PAS back in at the front.
• Loosely refit exhaust and heat-shield.
• Fill with oil and coolant.
• Refit ECU and plug loom in.
• Plug in all wire connectors to engine.
• Refit fuel-rail and pipes.
• Refit turbo and exhaust-manifold.
• Refit rocker-cover and injectors.
• Refit inlet-manifold.
• Attempt start!

NOTE: Fasten engine-mount top nuts! Neaten up fuel-rail return pipe!

Well, sadly, it didn't fire right up in the first few tried like last time, but the battery has been sitting for a month and died quickly, so I will charge it overnight and have another crack tomorrow.

• Check for missing wire-connectors. Crank-sensor?
• Bleed injectors and check for rail pressure.
• Flywheel position sensor - is it a different flywheel? Swap to original.
• Check injector-leads for pulses with multimeter.
• High-pressure pump - does it need bleeding? Is it working?
• Is 'Service Due' warning affecting immobiliser?

If all these check out and it still won't go then I will have to get a computer on it and get some fault-codes. I'm back in work next week, without a break, so I should be able to bring the Launch home.

It's been a hella lot of work the last 6 days so it would have been nice to have the engine fire up on the third go like it did when I fitted the new cylinder head, but ah well, I'm full of optimism at the close of today.

Plastic T-piece nozzle snapped off in the injector leak-off hose. Luckily I got fuel pipes with the new engine [even though the pump itself was missing] and didn't have to buy a new one.

From an '03, to an '09 and now back to an '04 - this is the third head in the E60.

E60: Engine Swap Week - Day 5

• Attempt to lift gearbox underneath car.
• Lift engine back out.
• Fit gearbox to engine.
• Remove bonnet / A/C-duct.
• Lift engine and gearbox in together [mm to spare!].
• Fit prop-shaft.
• Fit gearbox mounts.
• Fit starter-motor.
• Fit oil filter/cooler.
• Fit alternator.
• Fit PAS-pump.
• Fit A/C compressor.
• Fit thermostat.
• Re-attach lower wiring-connectors.

• Loosely fit crank-pulley.
• Loosely attach main electric-cables to alt / starter.
• Loosely fit anti roll-bar.

NOTE: remember sump wire connector + tighten 10mm screw on gearbox!

Gearbox was getting nowhere from below with so little room under the car, so the engine came back out and we lifted the gearbox on very easily.

By removing the plastic air-con duct at the back and popping the bonnet lifters off so it lifts up vertical, it is possible to just about lift the engine and gearbox in together without lowering the subframe / rack.

Just the rads and injectors now and it's pretty much ready to start.

E60: Engine Swap Week - Day 4

Had a lost day yesterday when the engine didn't arrive. It only turned up at 1.30pm today, so I will have to concentrate on swapping over the high-pressure pump, flywheel and clutch, as well as removing the loom etc. ready to patch mine in. Lifting the engine in will have to wait until tomorrow.

• Replace steering-rack / subframe bolts entirely.
• Remove loom and vacuum-hoses from new engine.
• Swap over high-pressure fuel-pump.
• Fit flywheel and clutch.
• Remove oil filter/cooler and rocker-cover for lifting.
• Match engines entirely.
• Lift engine in.

Engine arrived at 1.30pm.

And was finally sat in the bay at 7.30pm.

E60: Engine Swap Week - Day 3

• Drop prop-shaft.
• Remove slave-cyl. / gearshift linkages.
• Drop gearbox.
• Lift engine out.
• Remove parts for new engine.

Once the prop was down it didn't take long at all to get the engine out. The gearbox is huge, but surprisingly light.

Prep for new engine:

• Remove clutch.
• Remove flywheel.

Got the clutch off easy enough, but need a T55 Torx socket to remove the flywheel so that will have to wait until I get it from work tomorrow.

NOTE: Missing bolt from exhaust cross-member.

E60: Engine Rebuild 4 - Replacing Pistons, the easiest way.

EDITED August 2015:

** I never completed this job as I ended up replacing the entire engine, but did get pretty involved in it and thought I'd somewhat finish the guide anyway. **

If you're only replacing one or two pistons then the engine does not need to come out and the crank can stay on, but this is still a hardcore task. Still, I was determined to replace two of mine this way until a crack in the timing-case and other issues made me swap the engine, which was a lot more work and cost. Pistons are about £250 each new, but with 2nd-hand ones and new rings you could probably replace two for about £300, including gaskets and fluids. 

The biggest problem with accessing the bottom-end of the E60 engine is that the sump is an all-cast-alloy design that sits very snugly into the power-steering rack and front subframe. It also bolts completely to the gearbox bell-housing at one end. You will need an engine-crane to lift and support the engine an inch, then a bit of guts to unbolt and lower the subframe with the engine hanging precariously above you, so if this is beyond what you think you can do then it's time to bung the car over to someone with ramps, as you cannot get the sump off without doing it.

This thread on Bimmer-Forums [http://www.bimmerforums.co.uk/forum/f15/2003-e60-530d-whats-secret-getting-sump-off-please-t109192/] puts the process of trying to get the sump off without all the effort, then realising it is essential, quite succinctly and was a huge help for me.

You will need:

• Ramps
• Engine crane
• 1 or 2 Trolley jacks
• 1 or 2 spare Axle stands

You will need to remove:

• Cylinder head etc. [See this post].
• Engine under-trays and metal reinforcer-plate.
• Prop-shaft at gearbox end.
• Exhaust from back of turbo.
• Turbo hosing.
• Engine-mount top nuts.
• Front anti roll-bar centre-mounts.

Basic Process:

• Suspend the engine so the front is raised about one inch.
• Remove all the screws holding the sump to the block and the gearbox-housing.
• Unbolt the front subframe, the one the engine mounts sit on. The rear two bolts may not need fully removing.
• Have someone pry down the subframe and work the sump out from the rear of the engine.
• Bolt the sub-frame back up.
• Lower the engine back onto the mounts.
• Remove the bottom-end guard.
• Remove the big-end from the affected piston.
• Use a wooden drift to knock the piston(s) out of the top of the block.
• Fit the new piston(s) and repeat the process to refit the sump.

** As I say, I did not complete this job. I lifted the engine and lowered the subframe a bit, but could not get the sump out first try. A second try never came before I decided to engine swap, though I'm sure it would have come out. Refer to the thread linked above for far better instruction. **