e34_lover's E36 M3 Evo
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e34_lover
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Been busy working on my car trying to fix small niggles here and there as well as routine maintenance.
Having some slight idle issues so I removed my intake plenum to get to my idle control valve.
ICV
Dirty ICV
After cleaning
My electrical system has also been giving me some problems with a slight increase in voltage when I accelerate causing lights to go brighter. Removed my alternator to have a look at the voltage regulator.
Found this. As you can see, the brushes have been worn down. Spec is supposed to be minimum of 5mm, mine measures at 4mm. Hope the new regulator will solve the problem.
Will be removing my headers to fix a leak, changing my current KW V2 setup to some new AST's. So much work to come....
Having some slight idle issues so I removed my intake plenum to get to my idle control valve.
ICV
Dirty ICV
After cleaning
My electrical system has also been giving me some problems with a slight increase in voltage when I accelerate causing lights to go brighter. Removed my alternator to have a look at the voltage regulator.
Found this. As you can see, the brushes have been worn down. Spec is supposed to be minimum of 5mm, mine measures at 4mm. Hope the new regulator will solve the problem.
Will be removing my headers to fix a leak, changing my current KW V2 setup to some new AST's. So much work to come....
e34_lover
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Received a bunch of parts to fix my pedals.
Rubber pedals, new accelerator pedal, throttle cable and new bushings for all of them.
Accelerator pedal out
Didn't really like the M pedals already on the car
What was left of the old bushings. Accelerator pedal felt crap, wasn't smooth.
Because the bushings were worn/missing, the pedal was hitting the metal bracket that it sits in. This is the damage
New bushings
Modified an old clutch pedal bushing so that the new rubbers on the accelerator pedal don't get damaged like they did before
Everything fitted
Accelerator feels tight and smooth now, definitely give these parts a look if your accelerator feels crap.
Brake pedal
New rubber pedal
Old bushing
New ones
Clutch
Bushing removed
AKG delrin bushing
Old vs new bushing
Because the AKG bushings are made to such tight tolerances, they were really hard to fit because they are oversized. Had to remove them a few times with a lot of cursing because the circlips wouldn't go on as it was so tight coupled with lying down on the drivers footwell looking up with limited lighting... Install of only the clutch pedal bushings took about 2 hours. Was the pedal feel worth all the work? I believe so. Clutch feels really good now with absolutely no play at all. No more squeaking! :top:
Rubber pedals, new accelerator pedal, throttle cable and new bushings for all of them.
Accelerator pedal out
Didn't really like the M pedals already on the car
What was left of the old bushings. Accelerator pedal felt crap, wasn't smooth.
Because the bushings were worn/missing, the pedal was hitting the metal bracket that it sits in. This is the damage
New bushings
Modified an old clutch pedal bushing so that the new rubbers on the accelerator pedal don't get damaged like they did before
Everything fitted
Accelerator feels tight and smooth now, definitely give these parts a look if your accelerator feels crap.
Brake pedal
New rubber pedal
Old bushing
New ones
Clutch
Bushing removed
AKG delrin bushing
Old vs new bushing
Because the AKG bushings are made to such tight tolerances, they were really hard to fit because they are oversized. Had to remove them a few times with a lot of cursing because the circlips wouldn't go on as it was so tight coupled with lying down on the drivers footwell looking up with limited lighting... Install of only the clutch pedal bushings took about 2 hours. Was the pedal feel worth all the work? I believe so. Clutch feels really good now with absolutely no play at all. No more squeaking! :top:
e34_lover
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Removed my headers to get a leak fixed
Common problem with the flex joint cracking
Will be cleaning up the mating surfaces so I can get a good seal this time. I found that upon removal, there were leaks everywhere due to the nuts not being tightened properly.
Common problem with the flex joint cracking
Will be cleaning up the mating surfaces so I can get a good seal this time. I found that upon removal, there were leaks everywhere due to the nuts not being tightened properly.
e34_lover
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New exhaust gaskets
Decided to go for some torx head exhaust studs so that installation and removal in the future would be easier. The jam-nut method was a little hard at times due to the cramped space I was working in.
New copper exhaust nuts
Decided to go for some torx head exhaust studs so that installation and removal in the future would be easier. The jam-nut method was a little hard at times due to the cramped space I was working in.
New copper exhaust nuts
e34_lover
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Header mating surface
I don't really know why there should be any material on the header to cylinder head surface as it is supposed to be a metal on metal seal. Not sure what was put on by the mechanics that have worked on this car.
Heaps of rust on the header to cat connection
Car was running without gaskets when I bought it from the previous owner.
I don't really know why there should be any material on the header to cylinder head surface as it is supposed to be a metal on metal seal. Not sure what was put on by the mechanics that have worked on this car.
Heaps of rust on the header to cat connection
Car was running without gaskets when I bought it from the previous owner.
e34_lover
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Cylinder head cleaned up
Header mating surface cleaned
The cat connection was rusted badly so I had to sand it down
As you can see, some parts have dimples because of the rust. Decided not to sand it so deep and to leave it that way. New gaskets should seal it up nicely.
New flex joint welded in
Initially, I wanted to get the headers ceramic coated but decided against it. No real reason except for cost and the coating being unnecessary IMO. Bought some high temp manifold paint as well but after wire brushing most of the burnt on dirt, I felt that it would be too troublesome as the paint would probably flake off anyway. I have started to wire brush the headers in the pics but didn't really get any good shots of it
Header mating surface cleaned
The cat connection was rusted badly so I had to sand it down
As you can see, some parts have dimples because of the rust. Decided not to sand it so deep and to leave it that way. New gaskets should seal it up nicely.
New flex joint welded in
Initially, I wanted to get the headers ceramic coated but decided against it. No real reason except for cost and the coating being unnecessary IMO. Bought some high temp manifold paint as well but after wire brushing most of the burnt on dirt, I felt that it would be too troublesome as the paint would probably flake off anyway. I have started to wire brush the headers in the pics but didn't really get any good shots of it
e34_lover
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While the headers are out, might as well change the giubo. Had some looseness in the steering and clicking when turning the wheel quickly and knocking when the wheel goes over a bump because of the giubo flexing.
New part is slightly different. Have a feeling it is the same as the E46 M3 part.
Spent a few hours cleaning up the header heatshields and polishing them.
Befores
Afters
New part is slightly different. Have a feeling it is the same as the E46 M3 part.
Spent a few hours cleaning up the header heatshields and polishing them.
Befores
Afters
e34_lover
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Had a feeling my valve cover gasket was leaking
Removed my spark plugs
Found oil on the threads but I am not really sure if its there from a previous repair or if its a new problem. Tips are carbon fouled because the car has been running rich. Culprit would be the header flex joint leaking, header to cylinder head leaking as well as the O2 sensors being old. These leaks cause the O2 sensors to adjust the air fuel mixture because of the excess oxygen. Probably why I am down on power!
New ones were ordered and they weren't cheap....
New valve cover gasket
Not really sure if oil is supposed to be sitting on the gasket surface. Never done a valve cover gasket job before
New spark plug gasket next to the old one
Valve cover bolts washed
Rubber bits removed for stripping
Stripped, ready for some primer
Primer
New rubbers for the valve cover bolts
All done with new rubbers installed. Biggest pain in the butt installing the rubbers. They are such a tight fit....
Removed my spark plugs
Found oil on the threads but I am not really sure if its there from a previous repair or if its a new problem. Tips are carbon fouled because the car has been running rich. Culprit would be the header flex joint leaking, header to cylinder head leaking as well as the O2 sensors being old. These leaks cause the O2 sensors to adjust the air fuel mixture because of the excess oxygen. Probably why I am down on power!
New ones were ordered and they weren't cheap....
New valve cover gasket
Not really sure if oil is supposed to be sitting on the gasket surface. Never done a valve cover gasket job before
New spark plug gasket next to the old one
Valve cover bolts washed
Rubber bits removed for stripping
Stripped, ready for some primer
Primer
New rubbers for the valve cover bolts
All done with new rubbers installed. Biggest pain in the butt installing the rubbers. They are such a tight fit....
