My 530d M-Sport (Detail and wheels update pg 11)

sash

///Member
michael.joseph said:
Flip... that much for a new oem cooler. Ouch.

Can John maybe help with a better price.

Maybe try that place in Wynberg- Bavarian Breakers for a 2nd hand oem hopefully in good nic

That is the price from Leo Haese Hatfield, with Fanatics discount. :thumbdo:
 

sash

///Member
Fanatics to the rescue again...

While contemplating my options above Alex ( Tobofey) was chatting to me and he suggested another fanatic, Clive was in a similar position not too long ago. After chatting with Clive he pointed me to a place in West Modderfontein, that assisted him.

Spoke to the ever helpful Malcolm at Team Tombo Radiators, whose customer service is on par with the best i have seen. He checked and told me he had a Behr intercooler , brand new for me, at less than a quarter of BMW's price.

I couldn't, rather i wouldn't believe it until I saw it so i made arrangements to take the 70km odd drive from PTA to the shop. Getting there was the biggest hassle with JHB traffic in the middle of the day and roadworks etc. I get to the shop and Malcolm brings this.....

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I had my OEM one to compare and it matches 100%, proving again that BMW places a R6500 sticker made from unobtainuim

The two side by side

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tried to clean up everything as much as possible, including the Map sensor, Maf sensor, Fan, boost pipe, air temp sensor

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Was surprised about the amount of dirt that came out of the sensors...


Even with the air filter, I chose to go OEM, only to open the packaging and find this...

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my old one,
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I also decided to change the breather that fits on the tappet cover. Managed to order an OEM from Leo Haese and the part was ready for pickup the next day.

My old one didn't look bad, but the main filter on the inside cant be seen.
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Its a bit of a squeeze to get the part in and out of its position, but I most grateful that BMW decided to use bolts that do not come off the part.

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While in cleaning mode, I realised that the scuttle drain on the E60 is normally a problem, which can cause water build up and eventually if it collects enough can cause damage. ON my car i noticed that well after washing i would still get water dripping on the right side of the car, in my garage, so this was a must for me. I managed to only get one pic as I was trying to finish up the car. I vacuumed the entire area after the pic was taken and the drain cleaned.

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Then it was matter of buttoning everything back up and getting the car on the road to test.
Starting to look better.

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All done
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Kinda sticks out like a sore thumb, but for some reason i prefer this look over painting it.
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GoCart

///Member
Fantastic work Sash :clapper:

That there might be a time machine, as your quality work is taking the years off the big diesel :coolShake:
 

graan13

Active member
Sash, how did you know there was a problem - just a leak spot or were there other symptoms? Ouch....that is a price!! I dont understand how BMW charge soooo much more for parts........:hammerhead:
 

sash

///Member
Rayzor said:
Excellent work Sash. We need a Report on how she feels on the road now please.

Was chatting to Niks and was telling him i hardly use WOT, did a couple of pulls before cleaning the sensors and just 2 after cleaning sensors and while it is difficult to explain i noticed the following:

- The car changes gears better, for e.g previously in say 3rd, it would only change at 1650-1700rpm to 4th, now it changes slightly lower, around 1550-1600 ( its a small difference, but i notice it when driving at low speeds and you want to keep you revs low) When it does get into 4th, previously it would change to 3rd as soon as it gets to about 1100rpm, but now it goes down to 1000rpm when cruising, so not labouring at all.
- I notice there is significantly less lag in lower gears and even some improvement in the higher gears, which i didn't think was there, until I felt the improvement.
- In terms on consumption, I got stuck in unusual traffic so i can't compare my consumption for the trip( although with the traffic i still managed to match my previous consumption which already indicates an improvement), but on the same stretch of road i use the cruise control everyday, it would use about 9.5l/100km on the hill at 100km/h, this morning same stretch, the needle didn't go past 8.5l/100km, which i believe is a massive improvement on an incline.
- I have not yet tested WOT and higher speeds, but there is a definite improvement around 3000rpm.
- I did try a 0-100 video......



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michael.joseph said:
Nicely done Sash. And at a fraction of the price. U must be smiling from ear to ear
You have no idea..., i am all for OEM parts, but even more for value for money and quality and if the very same manufacturer is producing the same item then we know the quality.
 

sash

///Member
Cornel said:
it looks proper elder!

well done on the attention of detail

it takes me double maybe triple the time, but so worth it.


GoCart said:
Fantastic work Sash :clapper:

That there might be a time machine, as your quality work is taking the years off the big diesel :coolShake:

I would like to think so. I have always been a preventative maintenance person. I probably spend more and unnecessarily, but it pays off in the end.


graan13 said:
Sash, how did you know there was a problem - just a leak spot or were there other symptoms? Ouch....that is a price!! I dont understand how BMW charge soooo much more for parts........:hammerhead:

It first started by noticing the engine cover was getting slightly wet, then more recently i noticed the bottom left of the intercooler (when looking through the grills from the front) was starting get wet and dirty. Normally the leak is at the seals at the pipe and the oil would leak onto the engine cover and possible move towards the back of the car, but for it to show in front was worrying. While i started cleaning and changing one part, I normally consider what other part in the chain might need cleaning or replacement. This is where my fellow fanatics come in normally give the best advice.

Theres other symptoms like the gear change and lag, which i read about, but that could be other issues as well, so I was also holding thumbs.

Have to say thanks again to those who offered advice, information, tools, recommendations. My Diesel addicts/fanatics who are just a message away.


Sleepa said:
Glad you sorted it all out!

Car must feel like new now.

Well done.

Me more than anyone, I felt bad driving the car and knowing there was a potential issue, but i babied it for so long it changed my driving style.
 

sash

///Member
Peter@AEW said:
Well executed Sash glad to see you getting down and dirty :)

Thank you, It was you who mentioned way back then that these cars are not too bad to work on and gave the first tutorial on the oil change.
 

sash

///Member
Small updates, but updates nonetheless.

While the car was in pieces, i decided to finally bite the bullet and paint the grills. They were a bit pitted from the 180000 odd km it has travelled, so i was not looking for a perfect gloss finish.

Removed them, sanded each piece down with varying grit sandpapers, ending with 1500. Primered and sanded with 2500 waterpaper and it was as smooth as it could be without having to fill in some of the pitting.

Gave them a couple coats of black paint ( made for plastic, so will see how it holds up).
Didn't take much pics during as I just wanted to finish the job.

During
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After : Without Stripes, was contemplating this look for a bit. There was varying amounts of gloss based on how the paint was applied.
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But i prefer this look. I also lightly wet sanded and polished them to even out the gloss, so now the bezel part looks more even.
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I was also overdue for alignment and balancing so hopped on over to Hi-Q Dastek
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Safe to say, no damage to the wheels, but I worry about the fact that they are not able to adjust camber in front, but my values changed after they adjusted other aspects of the front alignment?
 

sash

///Member
After all the effort of removing and replacing the intercooler.... I see this
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