I picked up some 3.5mm hose from Verocious Motorsports.
Old vs new
The lines are mostly on the passenger side of the engine and the two wastegate lines are the hardest to replace; not sure how someone who has larger arms would have managed installing them from above.
I also decided I wanted to ditch the charge pipe for a proper one from Evolution Racing
However, what they sent wasn't quite complete:
They advised me that "Our charge pipe requires you to use the factory elbow that is on the factory charge pipe. You need to remove it and install it on the new charge pipe. The silicone coupler is included for customer who are installing the charge pipe on aftermarket intercooler systems. If you want to replace the elbow, the elbow section is replaced in our intercooler system."
Which is fine if you want to take apart your factory charge pipe and use an old rubber connector on a new charge pipe, which I didn't. Quick trip to Amazon fixed that with a 45 Degree High Temperature Silicone Elbow Coupler Hose
Here it is attached to the new charge pipe as compared to the old:
I didn't want to crank down the T-bolt clamps too tight and the first time I drove it around the block the connection from the 45 degree hose to the charge pipe popped off but 5 minutes later it was working as intended. The BOV (Tial) is pretty subdued which I think fits the character of the car.
30FF fault has not returned.
Got the KW V3 installed. Took a bit of time as I replaced the front lower rear control arms (because I mangled the top of them while removing them).
If I have to do this again I am going to buy this schwaben tool from ECS:
I also used this tool to separate the part that pinches the front struts:
You also need a strut socket to match the size of the top bolt. I think the KW V3 one was larger than the BMW one. My tool didn't fit inside the strut mount. Used a bench grinder on the tool to make it smaller so it fit. Still tight but made it work.
Car up on jack stands:
Released air from the rear springs per the Bentley manual:
New vs. old rear shocks:
Rear shocks installed, I also replaced all of the brake lines at the same time, I needed to bleed the brakes per the car anyway so I thought I would be proactive and replace them.
New lower rear control arms and new tie rod ends, definitely needed to replace the pinch bolts as they were quite rusty. Also the driver's side tie rod end was quite a pain to get off.
Also used this opportunity to remove the clutch delay valve (removed in this photo):
I drilled small holes in the carpet and plastic in the back of the wagon so that I can get an Allen wrench through the floor to adjust the rear shocks. You can't even see them so I left a couple pieces of tape so I could more easily find them. The rest of the adjustments you can get to more easily.
Initial impressions are that the old shocks (84k miles) were definitely worn out. I can feel the road variations more. Not nearly as much body roll. Still feels like a big car though but coming from a 911 it's probably hard to compare. Unfortunately it is also winter here so I did not try it on the BBS/summer tires.
I will post more impressions once I get the car aligned on Wednesday. The fronts are still a 1/2 inch higher than the rear. Will have them level it too.
Might be a while before I install these: AR design downpipes with cats
Car was at the mechanic recently to see if he could help me track down a vibration during acceleration.
Here is what they did (in order after consultations several times with me under the car):
-Installed the new index 12 injectors
-Re-balanced my winter rims/tires (they told me a couple of them are bent so I will be looking to replace them next year).
-Checked the Guibo (looked okay)
-Checked the transmission and engine mounts (looked okay)
-Rebuilt the rear driveshaft
-Replaced the front lower control arm bushings (inner)
-Replaced the front driver's side axle
I still have some vibration during hard acceleration. It is not quite as severe. Mechanic thinks it might be flywheel related. At least now all of the front suspension bushings are new and the front axles are new.
I also followed another thread here and put in the E61 M5 rear sway bar:
E61 LCI M5 Wagon Rear Bar
The E61 LCI M5 Wagon Rear Swaybar Bushings: 33551096701