MSpired's M3 came to us a couple weeks ago. He asked us to install our stage 2.5 turbo kit on his M3 and utilize his existing motor from his prior VF stage 3 build. When we (John and ChrisK) disassembled the motor we found that the piston to wall clearance was too high and this was most likely the cause to his excessive oil burning problems. As a result, Mike had to source and ship us a new "used" block, which will be arriving here shortly for us to build.
Many people have asked how his car is doing, so our techs documented everything they found along the way that will be cleaned up and fixed on assembly. Here's a complete list with pictures. I want to point out that our techs are very anal. In many cases there is nothing wrong with using an incorrect fastener but they make sure that all OEM fasteners go into their intended locations. I also want to point out that we do not know specifically who was responsible for these mistakes but they do exist on his car today and we will be fixing them all.
Issues with car upon arrival
- Car consumes excessive oil
- Driver's seat loose, poorly mounted to bracket and the seat is torn at belt loop
- Modded air valve wiring
- Tranny mount supports are installed upside down
- C exhaust pipe has a hole in it - has been attempted to be fixed but still leaks
- B pipe exhaust support bushing is broken off causing it to hit the rear V brace
- Misc wiring secured to chassis with wood screws
- Very poor aftermarket sensor wiring
- Missing header/frame heat shield fasteners
- Wiring is ran from engine bay through both doors to electronics inside
- Front sway bar endlinks bind
- RTV on rear section to c pipe exhaust gaskets
- Both power steering lines are damaged
- Crank angle sensor is loose
- Headers rest against the motor mount
- Air temp sensor wiring is very poor and it's ziptied to brake duct bracket
- Moisture in both corner lights
- Very poor meth/nos wiring on passenger side of car
- Methanol pump is mounted to the windshield reservoir and wired very poorly
- Poor angel eye wiring
- Right rear wheel is curbed
- Front brake lines are ziptied to coilovers instead of their OE bracket
- Differential has a lot of "slop"
- Missing injector connector retainer 1, all fuel injector to rail clips and fuel rail to fee line clip
- Coolant rail o-rings are covered in RTV - no RTV should be here
- Coolant rail to head o-rings covered in RTV and rail - no RTV should be here
- Copper spray was on head gasket - no copper spray should be here
- Cam cap nuts lock-tighted on and shouldn't have been
- EGT harness damaged
- Oil filter housing gasket to block covered in RTV - no RTV should be here
- Cam caps installed incorrect in wrong positions
- Rocker arm rail plugs rtv to head - no RTV should be here
- Oil pan rtv to block
- Drivers side lower A arm boost is installed incorrectly
- Piston to Cylinder Wall Clearance is too wide causing excessive oil blowby
Parts Ordered
- Missing fan shroud, fan, left and right deflectors and fasteners that connect the fan to the clutch.
- Missing all core support / coolant line clips
- Incorrect water pump fasteners
- Incorrect fuel rail fasteners
- LF fender liner missing. RF fender liner damaged, both are missing fasteners
- Incorrect drivers side ballast bracket and missing cover and fasteners
- Missing 1 RF wheel lug
- Incorrect front sway bar mounting fasteners - 4 nuts
- Incorrect charcoal canister cover fasteners - 3 nuts
- Power steering line has been cut, leaks and quick disconnect fittings have been broken
- Oil pan drain plug area damaged, beyond repairable
- Incorrect power steering line isolator
- Incorrect fasteners in center exhaust support - 3 bolts
- Incorrect fastener in driveline heat shield - 1 bolt
- Missing drivers rear sway bar mount fasteners - 2 allen bolts
- Passenger rear control arm bent
- All 3 rear section exhaust bushings need to be replaced
- 2 rear section exhaust bushing support brackets needed
- Incorrect rear section bushing fasteners to body - 6 nuts
- Incorrect rear section to bushing fasteners - 3 bolts, 3 washers
- Center section exhaust bushing missing - broken off of exhaust
- Missing bellhousing dust shield fastener - 1 bolt
- Missing bumper support fasteners - 1 nut, 4 self tapping screws
- Missing drip tray drain grommet
- PCV cap/line on engine cover broken
- Incorrect coil harness ground fastener
- Incorrect EGT/air pump nuts on head - 2 copper nuts
- Incorrect coolant reservoir mounting fasteners - 1 plastic insert and 1 self tapping screw
- Wire harness main fastener stripper
- Front right brake line is damaged
- Slip joint exhaust gasket bad
- Missing shifter bearing collars
- Incorrect IAC fasteners
- Incorrect throttle motor fasteners
- Power steering pump fasteners bent
- Power steering pump rear bracket modded beyond repair -- not available oe without purchase of pump
- Incorrect coolant rail fasteners, o-rings covered in RTV
- Oil dip stick missing washer, incorrect fastener
- Incorrect vanos line holder fastener
- Needs new thermostat and o-ring
- Coolant rail to head o-rings
- New water pump - covered in RTV
- New water pump gasket & o-ring
- Cam cap studs - 2 long, 2 short
- Constant oil pressure valve - covered in RTV
- Dowel pins for head to block
- Oil cooler hard line broken
- Power steering reservoir - pump line wrong
- Incorrect lower radiator hose clamp
- Missing rear head support bar fastener
- Rear lower pass ball joint
- New oil pump
- Incorrect oil pan fasteners
- Missing injector connector retainer - 1
- B pipe exhaust support bushing is broken off causing it to hit the rear V brace, will require modification to existing pipe to work properly
Car rolling in
http://www.60-130.com/images/imported/2010/03/476.jpg
Customer Requests Clean up of Brace Welds
http://www.60-130.com/images/imported/2010/03/477.jpg
Missing Lug
http://www.60-130.com/images/imported/2010/03/478.jpg
Bent Muffler Brackets
http://www.60-130.com/images/imported/2010/03/479.jpg
http://www.60-130.com/images/imported/2010/03/480.jpg
Bent Right Lower Control Arm
http://www.60-130.com/images/imported/2010/03/481.jpg
Brake Line Damage
http://www.60-130.com/images/imported/2010/03/482.jpg
Broken Exhaust Gasket
http://www.60-130.com/images/imported/2010/03/483.jpg
http://www.60-130.com/images/imported/2010/03/484.jpg
Broken Exhaust Mount
http://www.60-130.com/images/imported/2010/03/485.jpg
Sealant on Constant Pressure Valve - This Is Supposed to Seal with an O-ring
http://www.60-130.com/images/imported/2010/03/486.jpg
Crank Position Sensor Not Secured - Oil Leaking Out
http://www.60-130.com/images/imported/2010/03/487.jpg
http://www.60-130.com/images/imported/2010/03/488.jpg
Cut and Leaking Power Steering Line
http://www.60-130.com/images/imported/2010/03/489.jpg
Cut Shock Tower Stud
http://www.60-130.com/images/imported/2010/03/490.jpg
Damaged Air Duct Brackets
http://www.60-130.com/images/imported/2010/03/491.jpg
http://www.60-130.com/images/imported/2010/03/492.jpg
Bent Power Steering Pump Fasteners
http://www.60-130.com/images/imported/2010/03/493.jpg
Damaged EGT Wiring
http://www.60-130.com/images/imported/2010/03/494.jpg
Damaged Fender Liners
http://www.60-130.com/images/imported/2010/03/495.jpg
http://www.60-130.com/images/imported/2010/03/496.jpg
http://www.60-130.com/images/imported/2010/03/497.jpg
Dent in Piston not caused by engine operation
http://www.60-130.com/images/imported/2010/03/498.jpg
End Link Damage
http://www.60-130.com/images/imported/2010/03/499.jpg
End Link Not Secure
http://www.60-130.com/images/imported/2010/03/500.jpg
http://www.60-130.com/images/imported/2010/03/501.jpg
Here's the block with the head off and copper spray removed
http://www.60-130.com/images/imported/2010/03/502.jpg
Excessive Loctite on Flywheel Fasteners
http://www.60-130.com/images/imported/2010/03/503.jpg
http://www.60-130.com/images/imported/2010/03/504.jpg
No sealant should be used on Oil Filter Housing - This uses an O-ring gasket
http://www.60-130.com/images/imported/2010/03/505.jpg
No Sealant Should be used on Thermostat Housing - This uses an O-ring gasket
http://www.60-130.com/images/imported/2010/03/506.jpg
http://www.60-130.com/images/imported/2010/03/507.jpg
Excessive Sealant on Vanos
http://www.60-130.com/images/imported/2010/03/508.jpg
Exhaust Damage
http://www.60-130.com/images/imported/2010/03/509.jpg
