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TAB & StPike75 Reset Coolant Bomb & Trek through the Valley for Guides to 300k miles

TAB has reached the danger zone of 150-175,000 miles for the M62TU. No significant noises on start up, but realizing the odds are stacked to "when, not if" I have decided to tackle the guides while conducting a cooling system overhaul with Valley Pan Gasket. The cooling system is pushing 80k and the Valley Pan has a weep resulting in an occasional temperature foray to 110 before going back to 106-108. I will be replacing the Valley Pan and upgrading to the Zionsville system. So while I am in there... And as long as I am doing this I might as well do some other things (oil separator, vacuum lines, VANOS, ...).

StPike75 hasn't any cooling system or valley pan issues but did have the "every 5th start" rattle at 121k miles on the iT. That has since quieted with an oil swap to 0w40. The final listing of components for StPike75 may be significantly shorter.

We have decided to go as a team: he will assist me and I will assist him. Not simultaneously as out schedules won't allow for that but having two sets of eyes and hands should make the job a little easier. Not to mention that having two people should make documentation better and easier.

As for the materials I have gone for the FCPEURO kits and supplemental items and will be getting the GAS Master Cam Timing Tool Kit. The procedures are being assembled/condensed/created from an amalgamation of the sources at the bottom of the post and will be attached when completed. As I am expecting to go in August, I wanted to double check with the forum before the procedures so as to avoid the "when I guess I need to overnight that..."

So the questions for the community:
  1. are we missing anything in our material lists?
  2. anything else while we are in there?
  3. anyone in the Northern Virginia area have the various supplemental tools (crank/pulley holder(s), VANOS press, etc)? I say NoVA for geography reference but can work with shipping.
  4. (when added) any points on our procedures?

Vehicle Information
VehicleYearModelMileage
TAB2003540iA160k
StPike751999540iT121k

Sources of Inspiration, Information, and Procedures:
Around the M62TU in 80 Hours More or Less
GAS Master Instructions
m62 diy lower timing case removal and chain guide parts list
And of course the Bentleys.

Table of Parts
SystemNomenclaturePart#QTY
Belts & PulleysBMW Serpentine Belt - Contitech7PK16351
BMW Drive Belt Tensioner Assembly - INA112-87-515-8651
BMW A/C Drive Belt Tensioner - INA112-81-742-8591
BMW Belt Tensior Lever - Genuine BMW112-81-747-4591
BMW A/C Accessory Drive Belt Tensioner - INA112-81-745-5451
BMW Drive Belt Tensioner- OEM Supplier112-81-709-6131
Cooling SystemBMW Radiator Hose Lower (E38 E39 E52) - OEM Rein115-37-505-2291
BMW Coolant Hose (E38 E39) - OEM Rein115-37-511-2071
BMW Coolant Hose (E38 E39) - OEM Rein115-31-711-3851
BMW Heater Hose - Rein642-18-387-5211
BMW Coolant Hose (525i 528i 530i 540i) - Rein642-18-367-9291
BMW Coolant Hose (Heater Valve to ) - Rein642-18-391-0051
BMW Coolant Hose (525i 528i 530i 540i) - Rein642-18-391-0171
BMW Radiator Hose Upper - Genuine BMW115-37-505-2281
BMW Coolant/Antifreeze (1 Gallon) - Genuine BMW821-41-467-7041
BMW Expansion Tank Hose - CRP171-11-427-1561
BMW Expansion Tank Hose - OEM Rein115-31-711-3811
BMW Hose - Genuine BMW116-11-440-1271
BMW Auxiliary Fan Switch - Meistersatz136-21-433-0771
BMW Water Pump (540i 740i X5) - Hepu115-10-393-3361
BMW Coolant/Antifreeze (1 Gallon) - Genuine BMW821-41-467-7042
BMW Coolant Drain Plug Crush Ring - Genuine BMW71-19-963-2252
BMW Water Pipe (540i 740i 740iL) - OEM Rein115-31-711-3841
MaintenanceBMW Oil Filter Kit - Mann114-27-510-7171
ManifoldBMW Crankcase Vent Valve - Meyle116-17-501-5631
BMW Intake Manifold Gasket Rear - OEM Supplier116-11-729-7281
BMW Oil Separator (540 740) - Genuine BMW111-51-705-2721
BMW Oil Line O-Ring (540i 740i) - Genuine BMW111-51-439-9892
BMW Oil Separator Hose (540i 740i 740iL) - Genuine BMW111-51-705-3011
BMW PCV Breather O-Ring (E39 E38 X5) - Genuine BMW111-51-702-2911
BMW Intake Manifold Hose - Kayser116-11-742-8261
BMW Oil Seperator Seal - Reinz111-51-747-0481
TimingBMW Timing Chain Tensioner O-Ring Seal - Genuine BMW71-19-906-3611
BMW Oil Pan Gasket - Reinz111-31-436-3241
BMW Gasket Ring (A18X22) - Genuine BMW71-19-963-3001
BMW Position Sensor O-Ring - CRP121-41-748-3982
BMW Gasket Ring - Elring71-19-963-3551
BMW Oil Drain Plug Gasket - Reinz71-19-963-1511
BMW Center Crankshaft Bolt - Genuine BMW112-31-736-5851
"BMW M62TU Timing Chain Kit - M62TUTIMINGKIT includes:"
Engine Timing Chain500344031
Engine Valve Cover Gasket Set ELR2663701
Engine Valve Cover Gasket Set ELR2663301
Engine Oil Drain Plug Gasket ELR2500072
Engine Valve Cover Grommet REI70333880016
Engine Valve Cover Washer Seal REI7028499006
Engine Water Pump Gasket CRP11511705408EC1
Engine Water Pump Gasket31-027236-001
Engine Timing Chain TensionerINA-55100041001
Engine Timing Chain Guide BMW113117412361
Engine Timing Chain Guide BMW113117454061
Engine Timing Chain Guide BMW113117417771
Engine Crankshaft Seal ELR5866761
Engine Timing Cover Gasket Set REI1531928011
Engine Timing Cover Seal Strip REI7033394001
Engine Timing Cover Seal Strip REI7033395001
Camshaft Adjust Solenoid Gasket REI7033393002
Vacuum SystemBMW Vacuum Hose Silicone (White With Black Stripe) - CRP117-47-797-1771
BMW Air Pump Vacuum Hose (540i 740i 740iL X5) - Genuine BMW117-31-438-1391
BMW Vacuum Hose Silicone (Blue With Black Stripe) - CRP117-47-797-0821
BMW Brake Booster Vacuum Valve - Kayser OEM116-11-440-1351
BMW Brake Booster Hose (E39 E38) - OEM Rein343-31-166-1401
BMW Vacuum Pipe (540i 740i X5) - Genuine BMW116-11-436-6441
Valley PanBMW Covering Cap - Genuine BMW137-11-741-0974
"BMW Valley Pan Replacement Kit (M62 M62TU) - M62VALLEYPANKIT includes:"
Valley Pan Cover BMW111417420421
Hex Bolt With Washer BMW711991504620
Engine Coolant Pipe O-Ring CRP11531710048EC2
Engine Coolant Pipe O-Ring CRP11531710055EC2
Water Accumulator Gasket REI7031832002
Engine Intake Manifold Gasket REI7131853004
Valley Pan Cover BMW111417361061
Engine Water Pump Gasket 3131-027236-001
Engine Intake Manifold Gasket CRP116117297281
Engine Intake Manifold Gasket REI7131826001
VANOSBMW Timing Chain Guide Clip Upper - Genuine BMW113-11-742-1762
BMW Timing Chain Guide Upper - Genuine BMW113-11-435-0284
BMW Timing Chain Upper - Iwis113-11-747-4372
 

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oh man that looks like fun... fluids, oil, coolant, atf for power steering.. sealants... loctight.. beer... and then more beer.. dang, I wish you were on the west coast.. are you planning on doing videos and pictures too?
 

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Giant breaker bar al ah, "Around the M62..." They are not much money, and seem to really be the hot thing breaking the Jesus nut.

Jim
 

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Discussion Starter #4
oh man that looks like fun... fluids, oil, coolant, atf for power steering.. sealants... loctight.. beer... and then more beer.. dang, I wish you were on the west coast.. are you planning on doing videos and pictures too?
That is our plan. Plenty of pics and vids both for our reference and the forums reference/amusement.
Giant breaker bar al ah, "Around the M62..." They are not much money, and seem to really be the hot thing breaking the Jesus nut.

Jim
On our "tools to get" list. Luckily a HF is near me so will be utilizing that to a great extent.
 

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Going to wade into mine likely... October. Same stuff. Going to hopefully wait until it cools off a bit and also need to collect a lot more parts.

Looking forward to reading all about your adventure!!!

Jim
 

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TAB is fantastic, he's been doing all the research!

Luckily, I get to contribute some by having a mess of hand tools.

I do want to throw out the questions of what assembly greases, lubricants and gasket goop we need to gather? I've used honda gasket sealant forever on bikes and the scoobie, but have never needed to seal a 90* corner.
 

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Discussion Starter #7
To get organized and ensure I have my parts (and let's be honest, provide a little parts porn) here are some snippets:

Belts and tensioners


Cooling/heating hoses


Manifold


Timing


Vacuum


Valley Pan


VANOS


Still to get/receive/picture:
VANOS seals
Tools
Zionsville

Sent from my iPhone using Tapatalk
 

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Master of none
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I also replaced the three (per side) metal hinged cam seals under the vanos housing. I didn't see the check valves that go behind the vanos solenoids on your list but the list is huge so maybe I overlooked them. And, new o rings for your egr pipe where it mates to the head. Mine were in a horrible state. I also chucked the torx bolts for my front intake cover and the ccv. I cleaned the old bolts from my valley pan in the parts washer and used them in place of the torx. The 3/4 drive breaker bar at HF worked great on my crank pulley bolt. I slipped a piece of schedule 40 gas pipe over it and she broke lose straight away. Home depot sells a pre-cut four foot length and it fits nicely on the HF breaker bar. If you have the ability to drop the trans, it's a good time to replace the rear main seal and rear engine cover gasket but you have to pull the flywheel. Maybe new trans and engine mounts. And those pesky o rings between the block and engine mount. I completed mine about a week ago and I have never heard such a quiet and smooth running engine with 180,000 miles on it. Have fun. I look forward to your posts.:thumbup:
 

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I also replaced the three (per side) metal hinged cam seals under the vanos housing. I didn't see the check valves that go behind the vanos solenoids on your list but the list is huge so maybe I overlooked them. And, new o rings for your egr pipe where it mates to the head. Mine were in a horrible state. I also chucked the torx bolts for my front intake cover and the ccv. I cleaned the old bolts from my valley pan in the parts washer and used them in place of the torx. The 3/4 drive breaker bar at HF worked great on my crank pulley bolt. I slipped a piece of schedule 40 gas pipe over it and she broke lose straight away. Home depot sells a pre-cut four foot length and it fits nicely on the HF breaker bar. If you have the ability to drop the trans, it's a good time to replace the rear main seal and rear engine cover gasket but you have to pull the flywheel. Maybe new trans and engine mounts. And those pesky o rings between the block and engine mount. I completed mine about a week ago and I have never heard such a quiet and smooth running engine with 180,000 miles on it. Have fun. I look forward to your posts.:thumbup:
Also, if you're draining the block you may want to get another gallon of coolant. I think I read the capacity is somewhere around 3 gallons on the M62 540i. I know mixing mine 50/50 it took more than one gallon of coolant. Not sure about the new radiator capacity though.
 

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To get organized and ensure I have my parts (and let's be honest, provide a little parts porn) here are some snippets:

Belts and tensioners


Cooling/heating hoses


Manifold


Timing


Vacuum


Valley Pan


VANOS


Still to get/receive/picture:
VANOS seals
Tools
Zionsville

Sent from my iPhone using Tapatalk
That's a beautiful thing to see.
 

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Hey Bear & StPike - awesome thread guys. I'm at 128k miles on my '99 740iL - the engine is running fine, but I know that this job is in my not too distant future. Will be keeping a close eye on what you two are doing and for any parts/tools/goop you haven't already ordered. Thanks and once again, awesome thread!
 

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Glutton for punishment
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I don't see Beer on the list.:D

Also, make sure to have:
1. a charged camera (mine always craps out because I forget to charge)- you need lots of pics. You will not remember where everything goes AND WE want to see the pics too!!!

2. a box of ziplock baggies and a marker

3. some cardboard for 1) punching in long and short bolts in a specific pattern 2) for laying dirty stuff on.

4. a bunch of shop towels (I buy the blue paper towels in bulk at costco)

5. cleaner, degreaser (it's easier to work on clean parts)

6. tap and die set (just in case)


And a tip you are probably aware of, IF you can start spraying the bolts you anticipate will be a PITA- start now... Do some spraying every day. I had pretty good luck with the new stuff from WD40.

Good Luck guys!! (If I were closer I'd come and help)
 

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Boost, yes the stuff that get overlooked!

Some masking tape to mark connectors!

Cleaners+++ would make sense to have a plastic tub and a pressure washer as well?

We may mount a go pro on time lapse, but then the world gets to see all the oopes
 

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Glutton for punishment
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Not sure if you need a pressure washer, just some towels and cleaner to get all the grime and built up gunk off of what you can reach.

You might also consider sending your injectors out for a rebuild as well. I did that when mine was down. Now I KNOW that they are operating optimally. Isn't too expensive and with over 100k on the clock it's not unreasonable.
 

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Injectors - we won't be able to send them away, because we can't afford the down time. We'll need to figure out what basic maintenance can be performed.
 

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Boost, yes the stuff that get overlooked!

Some masking tape to mark connectors!

Cleaners+++ would make sense to have a plastic tub and a pressure washer as well?

We may mount a go pro on time lapse, but then the world gets to see all the oopes
Last build I did I was able to rent a SafetyClean machine. Came in REAL handy for cleaning all the parts that need to be cleaned.

Jim
 

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We may mount a go pro on time lapse, but then the world gets to see all the oopes
sharing the oopses is a good learning experience for the masses...sheesh i wish ida known of the possible oopses when i got mine..made quite a few
 

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sharing the oopses is a good learning experience for the masses...sheesh i wish ida known of the possible oopses when i got mine..made quite a few
bluebee was very generous in sharing her oopses. They provide a learning experience for all, not just the person wrenching on the car.

Jim
 

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Glutton for punishment
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Injectors - we won't be able to send them away, because we can't afford the down time. We'll need to figure out what basic maintenance can be performed.
Can't afford the downtime? I hope you have a second vehicle around just in case.
Trust me that a 2 day project can quickly turn into something much longer... When I did my car (and it's not as involved as yours), I ran into several unanticipated issues which pushed the project by days.

If you have a second car, you won't rush worrying about down time. Take your time and do it only once!
 

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Discussion Starter #20
Can't afford the downtime? I hope you have a second vehicle around just in case.
Trust me that a 2 day project can quickly turn into something much longer... When I did my car (and it's not as involved as yours), I ran into several unanticipated issues which pushed the project by days.

If you have a second car, you won't rush worrying about down time. Take your time and do it only once!
True and while in there we will be Semper Gumby. The "secondary" vehicle for me is the wife's and kid transport so while possible that then cuts into work time etc. If needed might go the rental but planning should assist in overcoming obstacles.

We are also looking at doing some work prior so we have things ready for install. Things like getting injectors from a part out and rebuilding them vs getting new. Same with valve covers and having those powder coated now vice the. 3-7 day most local shops are saying. That gives us time for TAB and can repeat on the items for StPike75 then we will haves "spares" at the end we can make available to others. Planning and seeing what cost vs benefit is as we still have some time.
 
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