2002 540i Oil Separator? CCV? help with cloud of smoke issue. Video

[JimLev]

The valves will hit the tops of the flat top pistons.
At this point if you can't find BMW pistons you might as well try to machine the flat top pistons.
I think the BMW ones have a coating on them.
You need to make sure the diameter of your new pistons is the same as your old BMW pistons or you will end up getting piston slap in the bores.

[FredRC]

The valves will hit the tops of the flat top pistons.
At this point if you can't find BMW pistons you might as well try to machine the flat top pistons.
I think the BMW ones have a coating on them.
You need to make sure the diameter of your new pistons is the same as your old BMW pistons or you will end up getting piston slap in the bores.

Thanks Jim, yeah machining is reserved for worst case scenario, but I need to know that at least I have this option or I`ll freak out. At first look they seem to have more than enough material. Diameter is the same 91,99mm. BTW the flats are genuine BMW as well.
I can`t import as used parts aren`t allowed. I`ll keep looking for a few more days for the pocketed ones tought. Thanks man, have a nice weekend.

[geargrinder]

Really. Find the right pistons. The flat ones are not the right pistons.

I'd just warn you not to take "one guy got it to work" with caution.

You've already had a big disaster from compromising when there were warning signs and things were not exactly right.

Honestly you should just find a used motor someplace. If I were you I'd put the project on hold until I could do that. There's gotta be a used motor someplace in Brazil.

Remember: E38's as well as E39's, possibly Range Rover blocks also, as long as it is a TU.

[FredRC]

Well, here we are again, after a trouble year to say the least. Got a new Oil Pump, new Pistons, new camshafts and valves. Engine its in its final stages fo being assembled. But as usual, something needs to happen. Now the Sprocket and the Smaller Bolt of the drivers side camshaft is missing, can`t find it anywhere.

#12 and #11 in this diagram (the bolt actually looks a little bit different)
My question is, are these Sprockets the same for the entire M62 line? By pictures they look the same and have the same amount of teeth. I`m asking because it`s way easier to find them for the non Vanos M62.



Just to be clear, this is what I need.

[JimLev]

Fred, so you didn't look in RealOEM to confirm? GG going to be jumping all over you when he sees this, LOL.

According to RealOEM the exhaust sprocket is the same p/n and used on all of these V8's.
Part 11311741115 was found on the following vehicles:

• 5' E39   (04/1995 — 12/2003)
• 7' E38   (12/1994 — 07/2001)
• 8' E31   (12/1994 — 05/1999)
• X5 E53   (10/1998 — 09/2003)
• Z8 E52   (05/2002 — 07/2003)

[FredRC]

Fred, so you didn't look in RealOEM to confirm? GG going to be jumping all over you when he sees this, LOL.

According to RealOEM the exhaust sprocket is the same p/n and used on all of these V8's.
Part 11311741115 was found on the following vehicles:

• 5' E39   (04/1995 — 12/2003)
• 7' E38   (12/1994 — 07/2001)
• 8' E31   (12/1994 — 05/1999)
• X5 E53   (10/1998 — 09/2003)
• Z8 E52   (05/2002 — 07/2003)

Hi Jim, how have you been?
I usually check with BMWFans.info, there I got that it was used only from sept.98. Then at some vendor`s website it showed as being compatible across all the M62 lifespan. Thats why I got confused. Lesson learned, I`ll check with RealOem from now on. Thank you my friend!

[geargrinder]

That was my belief even without looking up. The non-TU uses the outer oval holes to bolt it down whereas the VANOS motor uses the center hole. I think that's the only diffrinz.

[capnmoench]

Man, I’m sorry for the resurrection, but I am very invested in this story now. I started looking into posts for my OSV / CCV smoking / vacuum issue and this post came up. It started as an OSV CCV and exploded! Talk about disappointment in the sludge, amazement in the finished, cleaned and assembled motor, then the disastrous end of that block and pistons. I almost choked up.

- - - Updated - - -

I want to send this guy parts from my donor car.

[FredRC]

Man, I’m sorry for the resurrection, but I am very invested in this story now. I started looking into posts for my OSV / CCV smoking / vacuum issue and this post came up. It started as an OSV CCV and exploded! Talk about disappointment in the sludge, amazement in the finished, cleaned and assembled motor, then the disastrous end of that block and pistons. I almost choked up.

- - - Updated - - -

I want to send this guy parts from my donor car.

Hi my friend, how are you? Yes, definitely it has been a sad year on car related matters for me. I always wanted a V8 (always wanted a 540i to be precise) and when I finally got one, had all this thrown at me over a simple valve seals job.

Sorry I never got back to you guys, you`ve been so helpful I should at least have kept you updated, but to be honest I was so demotivated over all this that I decided to let it go for a while. A lot of other bad things happened:I found out the mechanic was stealing parts, that some parts went missing or got broken, that he "lent" my brand new spare tire to a friend of his without asking me first and the guy drove away with it, I had to get the police involved to get it back. He broke 7 oil jets, bent 8 valves, broke the oil pump shaft, toasted the starter motor, lost a dozen of small parts, lost 3 camshafts that I had to rebuy, broke the transmission oil cooler valve.... I`m sure theres more, but so you guys get the idea.

I know I shouldn`t havre trusted him, and some of you warned me about how the parts were being stored, I was worried myself, but considering he had done work in my previous car (a 2001 e39) and always delivere a good result, I decided not to worry much.

So anyway, here we are, a year and half later. The mechanic was fired and the shop owner decided to share my loss. He hired a new mechanic, which is not a BMW specialist, but has some decent knowledge and its deeply invested, not like the other one who let the car sit for a month over simple problem. We sleeved the engine and I bought the correct TU pistons. Engine was mounted in the car, and timed with the timing tools, following the Beisan instructions and some youtube videos.

Covers were fitted everything was tighted up and for the first time in over a year the engine fired up. However, it is running really rough. Specially during idle. I`m sure the headers are also not tight enough cause it seems to have a lot of noise coming from where the headers are connected to the block.

However if I rev it to 1000-1200, It smooths out a lot. I ran INPA and got a lot of erros and codes that I`m not familiar with, and the mechanic, as well intetioned as he might be, doesn`t have much clue either. He thinks that it might be spark plugs, coils or injectors. But all were perfectly fine before the car entered the shop and they weren`t replaced.

I really don`t want tog o through all this just to give up right now, so I`ll post the erros I got from INPA here, and if you guys could give me some input, I would appreciate.

[FredRC]

Well, heres the list of erros I`m getting from INPA, hope you guys can help cause I don`t even know where to attack first.

E R R O R M E M O R Y R E P O R T -------------------------------------
Date: 07/26/19 18:22:05 ECU: ME72KWP0 JobStatus: OKAY Variant: ME72KWP0-------------------------------------------------------------
RESULT: 11 errors in error memory !-------------------------------------------------------------

98 Tank ventilation valve Output
Error frequency : 1 Logistic counter: 40
Engine speed 160.00 /min Engine temperature 51.00 Grd C Supply voltage 10.27 V Vehicle speed 0.00 km/h
Error currently available Error tested -- -- -- -- -- -- -- -- Signal-/Path discontinuity current, -- -- -- Signal-/Path discontinuity Initial, -- -- -- SCATT-active -- -- -- -- -- -------------------------------------------------------------

115 Hot film air mass meter
Error frequency : 1 Logistic counter: 40
Engine speed 920.00 /min Intake air temperature 33.75 Grd C angle DK oriented to DK-at stop 3.92 % DK ADC HFM 1.04 V
Error currently available Error tested -- -- -- -- -- -- -- voltage value to low current,

-- -- -- voltage value to low Initial, -- -- -- -- SCATT-active -- -- -- -- -- -------------------------------------------------------------

33 Camshaft control
Error frequency : 1 Logistic counter: 40
Engine speed 560.00 /min Engine temperature 51.00 Grd C wnwi1_u -1.00 Grad KW tanwrhf_0_A 64.71 % TV
Error currently available Error tested -- -- -- -- -- -- -- Adaptation value impact not plausible current, -- -- -- Adaptation value impact not plausible Initial, -- -- -- -- SCATT-active -- -- -- -- -- -------------------------------------------------------------

34 Camshaft control Bank 2
Error frequency : 1 Logistic counter: 40
Engine speed 560.00 /min Engine temperature 51.00 Grd C wnwi2_u -1.00 Grad KW tanwrhf_1_A 65.50 % TV
Error currently available Error tested -- -- -- --

-- -- -- Adaptation value impact not plausible current, -- -- -- Adaptation value impact not plausible Initial, -- -- -- -- SCATT-active -- -- -- -- -- -------------------------------------------------------------

62 Misfire detection, sum error,
Error frequency : 1 Logistic counter: 80
Engine speed 600.00 /min relative air charged (rl) 28.50 % Engine temperature -48.00 Grd C gas level 10.00 l
Error currently available Error tested -- -- -- -- -- -- damaging Cat. Error current, -- -- -- damaging Cat. Error Initial, -- -- -- -- -- SCATT-active -- -- -- -- -- -------------------------------------------------------------

54 Misfire detection Zyl.6,
Error frequency : 1 Logistic counter: 80
Engine speed 720.00 /min relative air charged (rl) 28.50 % Engine temperature -48.00 Grd C gas level 10.00 l
Error currently available Error tested

-- -- -- -- -- -- damaging Cat. Error current, -- -- -- damaging Cat. Error Initial, -- -- -- -- -- SCATT-active -- -- -- -- -- -------------------------------------------------------------

55 Misfire detection Zyl.3,
Error frequency : 1 Logistic counter: 80
Engine speed 720.00 /min relative air charged (rl) 28.50 % Engine temperature -48.00 Grd C gas level 10.00 l
Error currently available Error tested -- -- -- -- -- -- damaging Cat. Error current, -- -- -- damaging Cat. Error Initial, -- -- -- -- -- SCATT-active -- -- -- -- -- -------------------------------------------------------------

56 Misfire detection Zyl.7,
Error frequency : 1 Logistic counter: 80
Engine speed 720.00 /min relative air charged (rl) 28.50 % Engine temperature -48.00 Grd C

gas level 10.00 l
Error currently available Error tested -- -- -- -- -- -- damaging Cat. Error current, -- -- -- damaging Cat. Error Initial, -- -- -- -- -- SCATT-active -- -- -- -- -- -------------------------------------------------------------

51 Misfire detection Zyl.5,
Error frequency : 1 Logistic counter: 80
Engine speed 520.00 /min relative air charged (rl) 36.00 % Engine temperature -48.00 Grd C gas level 10.00 l
Error currently available Error tested -- -- -- -- -- -- damaging Cat. Error current, -- -- -- damaging Cat. Error Initial, -- -- -- -- -- SCATT-active -- -- -- -- -- -------------------------------------------------------------

5 Oxygen sensors-Heater for Kat (Bank2)
Error frequency : 1 Logistic counter: 40

tabgmf2 5.00 Grd C uhsv2 4.56 V phlsnh2 1.08 rinv2 0.00 Ohm
Error currently available Error tested -- -- -- -- -- -- Short circuit UBatt current, -- -- -- Short circuit UBatt Initial, -- -- -- -- -- SCATT-active -- -- -- -- -- -------------------------------------------------------------

18 Lambda-Probe2 for cat.
Error frequency : 1 Logistic counter: 40
exhaust temperature from Bank2 before ca 285.00 Grd C Time after start (tnse_u) 204.80 s rinv2 0.00 Ohm Sensor voltage v. Cat. Bank2 0.45 V
Error currently available Error tested -- -- -- -- -- -- -- -- Open circuit current, -- -- -- Open circuit Initial, -- -- -- SCATT-active --

[FredRC]

The only error I had before taking the engine apart wast this 98 Tank ventilation valve Output


All the others came after we put it back in the car.

[JimLev]

Hi Fred, got your PM. thought I'd answer here for the other guys to help out.
BMW-FC 33 and 34 are for the timing not set correctly or the vanos solenoids not working.
Make sure the 5 fuses in the back of the DME box are OK.

MAF 115 looks like a bad MAF or possibly air leaks that would also account for some misfires. The misfires could also be the intake manifold gaskets.
Get the timing straightened first, then clear all the codes and see what comes back.

Lambda Probes, make sure the wires to them are not pinched and the fuses in the DME box are OK.

Tank ventilation, check the solenoid coil to make sure it's not open. The solenoid is mounted on the drivers side head very close to the bank 2 vanos solenoid, they use the same connector, make sure the connectors aren't swapped.

Good luck Fred.

[FredRC]

Hi Fred, got your PM. thought I'd answer here for the other guys to help out.
BMW-FC 33 and 34 are for the timing not set correctly or the vanos solenoids not working.
Make sure the 5 fuses in the back of the DME box are OK.

MAF 115 looks like a bad MAF or possibly air leaks that would also account for some misfires. The misfires could also be the intake manifold gaskets.
Get the timing straightened first, then clear all the codes and see what comes back.

Lambda Probes, make sure the wires to them are not pinched and the fuses in the DME box are OK.

Tank ventilation, check the solenoid coil to make sure it's not open. The solenoid is mounted on the drivers side head very close to the bank 2 vanos solenoid, they use the same connector, make sure the connectors aren't swapped.

Good luck Fred.

Thank you my friend, sure, posting here is the best option so we can also help others, but there were so many threads created overnight I thought you migh miss this. Once I check everything you mentioned I`ll post the results here. Thank you once again!

[FredRC]

Just to add a little bit more of context, I went to the shop today and made a little video to show how its running. At this point all we have done is fix a crack at the intake boot and cleaned/tested the fuel injectors. Tomorrow e are going to tackle the other things you mentioned, Jim

[JimLev]

Fred, sound like you may have an exhaust leak.
The lifter sound pretty noisy too, get the oil pressure checked too.

[FredRC]

Humm, I`m not getting an oil light or oil pressure light right now? Should i check with a oil pressure tool? If so where? I remember reading somewhere that the lifters take a very long time to load stop being so noisy.

Yeah, I suspected of an exhaust leak but didn`t mentioned anything to check if you could notice it too. Gonna adress that.