Yesterday was another B9 “wrenchfest weekend” at the AutoBahn, with the awesome and talented help of Steve, George, Aaron, Pavel & Mike (later joining in were Micah, Jim, Fikret, and Jamie) we plowed through the punch list of work items. George and I started on Thursday and continued into Friday when Aaron and Pavel joined us, and then Steve (our lead mechanic) came early on Saturday, with the rest of the crew arriving at various times during that day. A little diagnostic work was also done on Aaron's 535 and Jamie's 535 cars
A lot of beer and food was consumed over these 3 days, not to mention the making of some great memories, along with a lot of laughs and storytelling. A special thanks to my awesome wife for all the cooking & baking and cleaning for this ‘event’... she’s the best!
On Thursday, George and I installed the sound & vibration deadening sheets in the interior; from the front firewall to the back parcel shelf… it came out quite nice! We also cleaned and painted a number of engine parts; hooked up the battery; removed a couple trim parts; and installed numerous other small items. Gas was then added to the fuel tank, in anticipation of Saturday’s planned attempt to ‘start the re-built Alpina B9 engine’
When Pavel and Aaron arrive on Friday, the work of completing the HVAC system install began, as well as installation of all four re-freshed brake calipers and new pads. Pavel hooked up all his testing contraptions and soon had confirmation that everything worked properly in the HVAC box he had re-built and partially installed months ago, e.g., pneumatic actuators, fans, etc. We discovered we had wrong expansion valve part (incorrect fitting size) which then stopped the complete hook up of the A/C lines to the box… but, we didn’t have the AC compressor (which subsequently arrived FedEx on Saturday from a fresh re-build) nor the newly ordered (and coming from Germany) receiver/dryer and pressure valve needed to complete the AC system anyway… so, that will now be added to the punch list for the next wrenching weekend in April.
Saturday was the day we were going to try to start the engine for the first time… so, the newly painted valve cover & gasket was installed; as well as numerous crankcase ventilation parts, cooling hoses, the ECU, the AFM, new fuel hoses to the level sender in fuel tank, etc. Testing then began to assure fuel was getting to the injectors… which led to the discovery of a sizeable fuel leak from a small hose back by the external fuel pump… that, was then replaced. The initial “turning of the key” was then to commence, but, the ignition switch literally fell apart when Steve turned the key (it had been flaky when Pavel was doing his HVAC testing the previous day)… so jumpering a couple wires became necessary to get ignition. First try, cranking but no start… further testing showed no spark. So, relays were checked, as were other connections, and it was soon discovered that a small connector to the ECU was not in place. Next try... cranking, a little pop, then several pops, then VAROOM!!!
Next, the cooling system was evacuated and BMW coolant and distilled water were added, engine was restarted, we check for leaks, tighten a few clamps, and success was concluded!!
We didn’t have the new brake system reservoir (awaiting delivery from Germany) so we didn’t finish-up adding in brake fluid and bleeding/testing the brakes (and clutch)… more punch list work for the next session!
Next, a few other issues were addressed, including the replacement of a split hard brake line back near the rear wheel (the long line coming from the master cylinder). The old one was then removed, and with a tube bender, the new line was matched to it and installed. A couple other minor things were addressed, wheels installed, jack stands removed, and the car was then loaded into the trailer for its journey to VSR for paint.
I plan to pick up the car in April when returning from a little winter vacation in FL
and re-assembly will then begin!! So, with any luck, maybe this summer we’ll be ready to go for the maiden voyage drive, but not in time for Vintage… stay tuned!
Here’s a summary of all the work completed this weekend and some associated pictures:
- removed remaining outside trim pieces
- cleaned-up & painted any remaining front, rear, or undercarriage spots needed
- installed vibration/ sound deadening material in interior floor& firewalls
- cleaned-up & painted numerous engine bay parts
- put fuel in tank
- installed exhaust holders
- installed e-brake holders
- installed wheel well parts
- installed all brake calipers and pads
- installed DS window gasket and glass
- installed valve cover & gasket
- installed crankcase ventilation parts
- installed cooling system hoses
- installed AFM
- installed intake muffler
- installed other ancillary engine parts
- installed ECU
- installed fuel hoses to level sending unit
- completed install of HVAC system & tested
- check all systems for GO, e.g., fuel, electrical, cooling, vacuum, harness, etc.
- started engine
- replaced ignition switch with one from the parts car
- replace hard brake line from master cylinder to rear
- loaded car in trailer
I'm sure one of the crew that videoed the engine starting will post it up in this thread, and maybe other pictures too. It was a fun and productive weekend... thanks guys, much appreciated!
-RoyW
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