I've always dreamt of a sleeper wagon and one day there was a good offer for one with rust problems of an acceptable magnitude. Here in Estonia, the roads are salted in the winter, that causes massive corrosion problems.
When I bought it, it had tiny summer wheels. Got some 17inch rims and winter tires.
The car had some minor problems with engine running smoothly and at some point eveng getting the cold engine to start. Eventually replaced the O2 sensor and MAF sensor to get it running well. When fixing the small problems I also replaced the exhaust system from the downpipe. While roubleshooting and trying to get it running some casualties were taken.
The idea was to have a reliable sunday cruiser. The way towards this started with rebuilding the entire brake system.
The calipers were extremely rusty. To get them clean, tried electrolysis. Worked like a charm.
Also took the entire rear axle out to get it into parts and clean it for painting and replacing all the bushes, hoses, tubes, parking brake system, shock absorbers, diff oil.
Also got the offset of the 17" wheels changed -40mm and rear widened about 30mm.
http://static3.nagi.ee/i/p/998/76/24969103c8c447_l.jpg
While working on the stance I also cut the OEM springs almost in half. Would not suggest with oem shock absorbers. The ride is not very enjoyable, specially when the roads are not in the best condition. The thought is to have air suspension at some point and then change the shock absorbers to something that fits the stiffness better.
Since the engine was way under-powered and not the smoothest 4-cylinder in the world, I was looking to replace it. Due to Estonian laws and availablily the selection was limited. I would have had a V8, but the prices for manual are quite high. We have here a lot of BMW engines and know-how about turbocharging one.
The final choice was a M52TUB28.
I started with rebuilding the engine. Got everything machined and cleaned. At first I thought I will just make a minor maintanance, but ended replacing almost everything.
While cleaning, I managed to destroy the double-vanos system. Since I have experience in working with VEMS ecu and controlling the double VANOS with infintely variable cam control is quite difficult. I decided to convert this to non-TU engine single-VANOS system. I also wanted to have a more simple manifold, and replaced it to M50B25 manifold, that is a known performance upgrade. I realised that there are a lot of differences between M52B28 and M52TUB28 engines. I had to replace all the cams, modify the vanos unit, close some ports for EGR and Idle control in the head. I also made some turbo oil return ports for bottom-mount turbo install in the future.
While rebuilding the engine, there was a good offer for a GT3071R turbocharger.
Then it was time to take out the old engine, give the engine bay a clean and get the new engine mounted.
The engine is coming from 5.seriers E39 and fits like it is meant to bethere.
After test-fitting everything, I repainted the engine compartment and other items.
The gearbox is a ZF unit that should handle the power. Stirring the gearbox oil with a long stick and short throw.
Since the windsheild wipers were a bit stuck and i anyway had to work on the pedals It made sense to remove the dashboard. When the dashboard is out, it also made sense to do some other works, that are easier.
Ended up with installing an audio amplifier hidden under the dashboard for under-seat subwoofers, installed keyless central locking and some other minor improvements.
This is VERY shortly summarising what has been done. There are a lot of small details
I'm now waiting for the ECU, shortening of the propshaft and finishing all the small bits of the swap.
A long way to go, but hoping to get it running before christmas
When I bought it, it had tiny summer wheels. Got some 17inch rims and winter tires.
The car had some minor problems with engine running smoothly and at some point eveng getting the cold engine to start. Eventually replaced the O2 sensor and MAF sensor to get it running well. When fixing the small problems I also replaced the exhaust system from the downpipe. While roubleshooting and trying to get it running some casualties were taken.
The idea was to have a reliable sunday cruiser. The way towards this started with rebuilding the entire brake system.
The calipers were extremely rusty. To get them clean, tried electrolysis. Worked like a charm.
Also took the entire rear axle out to get it into parts and clean it for painting and replacing all the bushes, hoses, tubes, parking brake system, shock absorbers, diff oil.
Also got the offset of the 17" wheels changed -40mm and rear widened about 30mm.
http://static3.nagi.ee/i/p/998/76/24969103c8c447_l.jpg
While working on the stance I also cut the OEM springs almost in half. Would not suggest with oem shock absorbers. The ride is not very enjoyable, specially when the roads are not in the best condition. The thought is to have air suspension at some point and then change the shock absorbers to something that fits the stiffness better.
Since the engine was way under-powered and not the smoothest 4-cylinder in the world, I was looking to replace it. Due to Estonian laws and availablily the selection was limited. I would have had a V8, but the prices for manual are quite high. We have here a lot of BMW engines and know-how about turbocharging one.
The final choice was a M52TUB28.
I started with rebuilding the engine. Got everything machined and cleaned. At first I thought I will just make a minor maintanance, but ended replacing almost everything.
While cleaning, I managed to destroy the double-vanos system. Since I have experience in working with VEMS ecu and controlling the double VANOS with infintely variable cam control is quite difficult. I decided to convert this to non-TU engine single-VANOS system. I also wanted to have a more simple manifold, and replaced it to M50B25 manifold, that is a known performance upgrade. I realised that there are a lot of differences between M52B28 and M52TUB28 engines. I had to replace all the cams, modify the vanos unit, close some ports for EGR and Idle control in the head. I also made some turbo oil return ports for bottom-mount turbo install in the future.
While rebuilding the engine, there was a good offer for a GT3071R turbocharger.
Then it was time to take out the old engine, give the engine bay a clean and get the new engine mounted.
The engine is coming from 5.seriers E39 and fits like it is meant to bethere.
After test-fitting everything, I repainted the engine compartment and other items.
The gearbox is a ZF unit that should handle the power. Stirring the gearbox oil with a long stick and short throw.
Since the windsheild wipers were a bit stuck and i anyway had to work on the pedals It made sense to remove the dashboard. When the dashboard is out, it also made sense to do some other works, that are easier.
Ended up with installing an audio amplifier hidden under the dashboard for under-seat subwoofers, installed keyless central locking and some other minor improvements.
This is VERY shortly summarising what has been done. There are a lot of small details
I'm now waiting for the ECU, shortening of the propshaft and finishing all the small bits of the swap.
A long way to go, but hoping to get it running before christmas