N47 Engine Rebuild

[stevepoulter]

Hi All,

Some of you may know that I had a timing chain failure on my 520d 2010 recently.

I am slowly but surely repairing the issue myself and currently I have removed the engine from the vehicle and it has now been completely stripped to its component parts. (Working full time is making the process very slow), anyways.....

I thought as I've got the engine out I may aswell re condition the engine. In regards to the timing chain failure, I think I've been extremely lucky. No broken rockers, No bent valves. The engine is in very good condition. I have cleaned everything (a horrible job) and all parts look brand new.

My question is in regards to what to replace when reconditioning the engine, I have never done this sort of work before but I am pretty good with my hands and extremely organised.

So far I have the following list of things to do:

Clean all engine parts DONE
Inspect all individual parts DONE
Re hone cylinders (lightly as they are in good condition)
Replace piston rings
Re seats all valves
Replace all stem seals
Replace ALL gaskets/Seals
Install new timing chain kit Inc Cam/Fuel Pump sprocket
Recondition fuel/oil pump


As I mentioned, the engine is in excellent condition, the Conrod bearing shells and crank bearing shells are spotless, without any scoring or minor scratches, I was shocked how new they look.

Would you recommend I replace ALL bearing shells now I've got the engine in pieces?

Is there anything else I should consider

Thanks all

[stevepoulter]

Thanks

It's done 90k and has a full history. Oil change was done to manufacturers schedule. Some people recommend more frequent changes.

I have been extremely lucky though, no real damage apart from timing case cover scored, broken fuel pump sprocket and obviously timing chain broken. Everything else seems fine.

[stevepoulter]

Al_85 said:

Hi, sorry to hear about this! Was there any prior warning to the chain going? EML or similar?

No warning, engine just cut out one day

[stevepoulter]

helix402 said:

I’d leave the bearings if they’re fine.

I've decided to replace the bearing shells both crank and Conrod. Thought I'd just regret it later on.

I am about confused about ordering new ones. Newtis states the shells must be replaced like for like, i.e. yellow, white, green.

Most places sell sets of shells and according to the print on my crank and crank case I require a mixture of yellow and green shells.

I have found them separately but they will more out significantly more expensive.

What is the difference between these colours? RealOEM shoes different types of each colour. I'm so confused.


UPDATE ON REBUILD:

All parts have been cleaned and today I started to polish the crank/cam journals. I have managed to get them sparking, if I say so myself, like mirrors.

Just awaiting the piston rings, and gaskets. The rings I ordered previously arrived broken.

Thanks all

[stevepoulter]

Update:

Finally finished the complete engine rebuild. Took me only 2 months ! I was only doing an hour or 2 here an there mind you.

Yesterday I managed to install the shiny like new engine, which took about 4 hours. It was a complete arse to get lined up the gearbox. But got there in the end.

Today I filled her with oil and gave her a few cranks with the injectors disconnected just to get oil to circulate the "dry" engine.

However, there are two bits I can't seem to work out where they live. 1) Connector 2) Bracket type thing

How do I attach pictures to this message?

Any help appreciated

[stevepoulter]

Haven't tried it yet, currently no coolant. I'm filling that tomorrow as I had to wait for the vacuum pump.

Going to plug it into ISTA before stating it just to bleed fuel, check pressure and cam/crank sync etc

Then it's the first fire up attempt.

Any idea how to attach pictures, maybe you could help find the home of these things

Edited by stevepoulter on Monday 7th January 22:25

[stevepoulter]

Right

These two images. The second one is a plug, which I can't find what it plugs into.

First is some bracket with a black gasket down one end.

I can't remember where these were from. Any ideas anyone

[stevepoulter]

First picture bracket home found

[stevepoulter]

All found and homed

[stevepoulter]

Update:

Did a vacuum test on the coolant system and there was a leak. After ages of searching for the location of the hissing I found the leak coming from the EGR, specifically one of the pipe union hoses.

Engine has now been filled with new oil, oil filters etc etc. Glow plugs are now responding in ISTA and have been set up

Just got to wait for the pipe union parts and remove the EGR and install new pipes.

Not long now

[stevepoulter]

Update:

Coolant check passed today after I replaced the union hose on the EGR.

Topped up oil and bleed fuel system with ISTA

When finally time to start the car the engine fired up after about 5 attempts !!!! Yay!

However.....

I am getting oil pressure too low error. Oil level is just about minimum.

Going to look into this more tomorrow

[stevepoulter]

All sorted.

Leaks/errors messages all clear.

Runs fine, only done about 20 miles of testing but no issues thus far. (Touch wood)

Does sound a bit louder than it used too but I assume this will be whilst the engine oils gets into all hydraulic lifters and parts. I did rebuild the engine and cleared absolutely everything, including emptying the lifters of old oil.

Time will tell.

Anyways....I now have various tools that I no longer need and I am looking to sell. Where is the best place to sell these.

I have Engine Stand, Engine Hoist, N47 Timing Kit, Piston ring pliers, piston ring comprrssor, valve spring removal/install tool, valve seals removal/install tool.