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Turbo replacement, coolant, ignition, VANOS work

E61 Touring Discussion The touring is also known as the wagon version of the 5 series.

Turbo replacement, coolant, ignition, VANOS work

Old 10-04-2018, 05:58 AM
  #11  
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Join Date: May 2013
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My Ride: 2010 535xiT Touring
Model Year: 2010
Engine: N54 3.0L Twin Turbo
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Progressing well - have everything pretty well removed from in front of the engine - ready to go underneath and do exhaust, driveshafts and axles. No doubt this needed major service - blocked cooling fins on most of the coolers, and huge crud under the inlet of the front turbocharger. I've done a posting with a bunch of photos here:

The Fix-it Blog - Sorting Things Out: BMW 535xiT Turbo Replacement Project - Prep for Pulling the Engine

Here's a few photos:


Oily crud under the front turbo inlet

Intercooler fins about 30% blocked with crud


Front bumper and coolers removed - time to move under the car to remove exhaust, axles and driveshafts.
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Old 10-04-2018, 07:09 AM
  #12  
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Model Year: 2009
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Looks like a good time
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Old 10-10-2018, 04:24 AM
  #13  
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Join Date: May 2013
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My Ride: 2010 535xiT Touring
Model Year: 2010
Engine: N54 3.0L Twin Turbo
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Progressing well now - everything is done in preparation to pull the engine - exhaust, driveshafts, front axles removed, electrical out of the way, all cooling and fluid hoses out of the way, intake removed. All that's left are the bellhousing and motor mount bolts - looks like I'll pull the engine on Thursday this week.

I put up a bunch of photos here: The Fix-it Blog - Sorting Things Out: 535xiT Turbo Project - Ready to Pull the Engine

Here's a few of the better photos:


Massive crud in the intake ports - will be walnut blasting.

Dewalt 20V 1/2" impact is your friend when removing the front axles and suspension components.
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Old 10-10-2018, 10:23 AM
  #14  
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My Ride: 2010, E61, 535i xDrive
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Looking at the blog details, project keeps on growing on scope...and cost! More nuts, bolts, sensors, coolers etc!
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Old 10-10-2018, 01:13 PM
  #15  
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Join Date: May 2013
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My Ride: 2010 535xiT Touring
Model Year: 2010
Engine: N54 3.0L Twin Turbo
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You're not kidding about scope and cost. I've spent the last 4 hours working on my Pelican parts order for all the miscellaneous driveline seals, o-rings, etc.... Will give you all a rundown on fhe final cost when I'm done. Once I'm done - I don't think the resale value of the car will reflect the cost of all the parts and some value for my time - just my feeling right now - will have to hold onto the car for a while to get my money's worth. No worries though - i still love driving this car - I just want my full turbo accelleration back.....
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Old 10-11-2018, 01:00 PM
  #16  
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Join Date: May 2013
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My Ride: 2010 535xiT Touring
Model Year: 2010
Engine: N54 3.0L Twin Turbo
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Engine and transmission are out - decided to take them out together and split them on the floor, which worked out pretty well. Pulled off the flywheel quickly - no signs of oil leakage from the rear main crankshaft seal - looks like oil from the rear turbo was making it through the block / bellhousing gap which looked like a rear main seal leak from below. There is massive oil leakage through the pan gasket, definitely needs to be replaced.
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Old 10-11-2018, 01:04 PM
  #17  
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Join Date: May 2013
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My Ride: 2010 535xiT Touring
Model Year: 2010
Engine: N54 3.0L Twin Turbo
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Engine and transmission on the hook.

On the ground.

Flywheel off, inspected the rear main - no leakage. Turbo oil leaks were getting into the bellhousing space.

Big open hole - tried to lift engine with transmission over the steering rack / subframe - but we had to drop the subframe to get the x-drive transfer case over the steering rack.
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Old 10-17-2018, 03:25 PM
  #18  
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Join Date: May 2013
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My Ride: 2010 535xiT Touring
Model Year: 2010
Engine: N54 3.0L Twin Turbo
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Got the new head gasket done today, along with new timing chain tensioner and Vanos Solenoids. Got the front and rear main crank seals done 2 days ago. Yesterday was a hit and run to Ottawa to drop off the steering rack and front driveshafts for rebuild at Axle Automotive. I'm finally starting to feel like this is progressing. Next up - install new turbos, valve cover, intake walnut blast and oil pan gasket.....

Block surface clean, ready for head gasket.

Pulled the idrive transfer case rear driveshaft output yoke to find the leak. Turned out to be the O-Ring leaking inside the yoke, just behind the splines. Have the parts from Pelican, ready to install.

Front main seal leak - now replaced.

Head off the engine, ready for cleanup.
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Old 10-17-2018, 07:49 PM
  #19  
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Model Year: 2009
Engine: N54
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Holy shit! Didn't know you were going that deep into this!? Wow man, props to you.
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Old 12-13-2018, 12:13 PM
  #20  
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Join Date: Aug 2018
Location: Abbotsford, BC
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My Ride: 535xi wagon 6MT
Model Year: 2009
Engine: N54
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Any updates? Been a while, I hope things are going well for you.
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