Give this man a Bells :clapper: Thanks for taking the time to write up such a comprehensive campaign.
In order to keep as much information (and accurate) available to the public I would like to add these 2 bits of info for now...
Valve clearances mentioned earlier won't be affected by valve stems. Valve seats however do wear somewhat during the engines life and this decreases the clearances. I have seen some shimms fall way below spec due to this. Intake range being 0.18mm to 0.23mm I've seen some as low as 0.05mm. This is frightening as once the valve floats it could lead to valve failure (lack of cooling from seating)
Generally speaking though the shimms wear toward the increasing and safer limit. commonly found to be around .35 on exh and .28 on intakes. Which increases fuel consumption and decreases performance. Also makes for a noisy valve train.
Further more some interesting facts about the Bearing issue.
Many have speculated the oil vs warmup vs fuel quality debacle. I personally believe fuel quality to be at fault. Obviously cold engine wear and abuse leads to all kinds of failure so assuming those are equal, fuel is our culprit.
Given the aggressive nature of the MSS54 and MSS54HP Ecu mapping the engine always runs into high ignition advance timing throughout the RPM range and essentially always "looks" for knock and then retards the timing. This increases wear on the top big end bearing shell. As can be seen by all the DIY's posted.
Interestingly I have been to the Middle east and with their superior fuel quality I have seen and driven several S54 S65 S85 engined M3 M5 M6 cars all of which had well over 150k kms. Some even as high as 243k kms.
Thats right Gents, E60M5 V10 with 243k kms on original bearings! I was simply stunned.
Lesson learnt by self is to always ensure at least an actual Ron value of 95 in your car to prolong bearing life. I'm sticking to my recipe of 1/4 NF ultra per tank and enjoying peace of mind.
Hope this adds something to the thread. No offence intended Adriaan. Just wanting to add some value.