老馬復康俱樂部 Old Horse Rehabilitation Center

老馬復康俱樂部 Old Horse Rehabilitation Center Passionated computer engineer dedicated on working every aspect of the E-series BMW, from engine repair to DME hardware upgrades, everything is done properly

After running the recently purchase car over 5000km, most of the issues has been identified, and purchasing all the nece...
20/01/2024

After running the recently purchase car over 5000km, most of the issues has been identified, and purchasing all the necessary parts for the major underneath replacement, hopefully can run for few more years without any issue.

Basically what have to do is, first to disconnect the o2 sensor, take off all the intake assembly, drain the coolant, hook the engine, unbolt engine mount, remove underbody protection, take off the exhaust, entire subframe, remove drive shafts, remove the front diff, remove oil pan and remove entire turbo...

It is a nightmare job for this n20, do it bit by bit over few days...

But it definitely worth if the owner wants to keep the car over few more years...

Main items have been done are...

Replace the turbo compressor with newer design
Replaced the improved oil feeding line for turbo
Replaced the upgraded oil return hose
Replaced the oil pan gasket
Replaced the oil pump chain guide as it was broken when removing the oil pan
Replaced the gasket along all the front diff
Replaced both front output shaft as both of them has serious leaks
Repaired the steering rack knocking noise using the kit and now steering is sharp again
Replaced the enhanced intake pipe from MST
Upgraded the diverted valve module
Upgraded the mickey mouse water hose yo aluminum version

After the repair, so far, running the car over 200km for the test drive, turbo is far more stronger and hold the boost better, and better fuel economy and more quiet engine on cold starts..

Glad to see a car is returning to her peak state again.

There is a refrigant smell when activating the blower, no matter it is ac on or off.This is very high chance on the refr...
02/12/2023

There is a refrigant smell when activating the blower, no matter it is ac on or off.

This is very high chance on the refrigant leaks in the evaporator...

This is a night mare job, need to take off all the dash panel, in order to access the air conditioning module, which is very time consuming.

Anyway, I am glad to see the evaporator that I take out is really leaking, thus can confirm I can fully fix the issue.

After everything is assembled back and test drive, no more refrigant smell and the car has been running over 1000km after fixing, no more bad smell.

Glad to see the ac system is back to normal again.

Retrofitting X3 HU_CHAMP2 -> HU_NBTThis topic is bit technical and normal user may not aware the difficulty of the proje...
02/12/2023

Retrofitting X3 HU_CHAMP2 -> HU_NBT

This topic is bit technical and normal user may not aware the difficulty of the project.

Let me explain in bit in-depth so that why changing options of the BMW need to manage a lot of things...

The story begins with the recent purhcase of the X3 and found that the iDrive screen of the car is just 6.5inch, and also the car does not have bluetooth service which only support USB to import songs..

One of my friend got a spare HeadUnit NBT(Next Big Thing as what BMW call). This headunit has the bluetooth function inside, which means if I want to upgrade, what I need do is to buy a 8.8inch iDrive monitor for this NBT and install.

Swapping is technically no challenge, however, making the hardware work does need some computer knowledge related to BMW coding and flashing.

I come from E-series background, while for F-series, I have no idea yet how to use e-sys, a coding and flashing utitlity for manging f-series cars..

The idea is very similiar, and which involves:
1) remove the old Vechicle Order option
2) add the correct option value for the newly installed component, for this time, it's Nav Profession with option code 609, in addition to that, I added the bluetooth option with code 6NS
3) then locate which modules are connected to the Head Unit, then we need to tell them the change of hardware, this process is called VO Coding, which the updated VO is now re-configure to related modules, for this time, the NBT is connected with 4 modules: NBT, KOMBI(Instrument Cluster), PDC(Parking Distance), ICM(I have no idea the full name)
4) once everything is coded, reboot the NBT and then the bluetooth feature is WORKING!
5) however, since the navigation require some FSC license, which it will be invalidated once the HeadUnit is switched to other car.
6) there are several ways to do, some of the people will go for non-technical approach, use a emulator to bypass the checking and then make the navigation working.
7) for me, as for technical study, I go for generating my own FSC code, and then apply to the HeadUnit via esys FSC module.

Navigation works like a charm after the FSC code is injected. Although the BMW navigation isn't that good when comparing with google, so it's just a nice to have feature.

Anyway, glad to see the car is equiping with a more modern feature, and better looking iDrive screen.

This is definitely an intensive experience to learn how an electric car work, the entire jounrey takes around 2 months, ...
29/09/2023

This is definitely an intensive experience to learn how an electric car work, the entire jounrey takes around 2 months, from a tesla with NO START symptom to make it RUNNING again.

For normal tesla no start, the most common fault is the AC compressor and battery heater got isolation leak, while for this car, it's something more difficult...

after a lot of study, research, trail and error, I finally managed to make the tesla back to RUNNING again.

It is a very good experience on troubleshooting isolation fault, and I learnt a lot from tesla motor club forum, therefore I posted my full journey to tesla motor club at below link:
https://teslamotorsclub.com/tmc/threads/model-s-late-2016-75d-isolation-fault-story.312640/

Hope it will help more people driving the tesla when encountering the NO START symptom.

To be honest, the technique between the petrol car and electric car is totally different as their powertrain system is totally different, the way to perform troubleshooting is completely different.

But when I look back the complexity of the electric car, seems it's more straightforward to troubleshoot, it's all about the delivery of electrical power to certain components and avoid leakage of the high voltage.

Anyway, i am happy to see a car back on road again.

Installation of backup camrra is something diyer can do, but it takes a lot of time to handle as the installation of wir...
12/07/2023

Installation of backup camrra is something diyer can do, but it takes a lot of time to handle as the installation of wire and storage of additional backup camera module makes the installation more challenging, need to detach a lot of parts to install.

The funny thing for this car is, when I hooked up everything and do some quick testing before installing back to position, the camera is not on.

I checked the voltage signal, it has 12V. While I probe the module, the voltage signal at the backup camera is 0V...

And find out that the power cord that bundled with the kit is somehow goes bad, then I find some plug that is compatible, then everything works like a charm.

For modern car, I think the reverse camera is a very good option to have.

This is an interesting case, which the car has been carefully maintained since last year, as the owner have a no start s...
12/07/2023

This is an interesting case, which the car has been carefully maintained since last year, as the owner have a no start symptoms past few year.

The owner is the first hand owner of the car since 2012, and the car is driving very normal during the first 8 years. And after that, the car start to failing fuel pump in the middle of the road.

In the first failure, the car was towed to bmw service center.

And they replaced the fuel pump, and with around 1 month of driving, the car stalled again.

Bmw service center replaced a brand new latest electronic fuel pump module for him during that time, and he is good with 1 year.

And after 1 year, the car stalls again, and I replaced the fuel pump for this car, and then he is good for another full year, until recently he called me the symptoms is returning...

For this time, i carefully probe the sensor and voltage, everything goes to the bad fuel pump.

While I am guessing the ekp may fail, but the ekp is with latest hardware version, and tested no short to ground issue.

So, I replace the fuel pump, the car starts right up again.

So far it is a mystery why the car failed the pump every year. Normally for the car with ekp module, the fuel pump will be very long lasting, like the one in my e90, the fuel pump last over 8 years already...

So far the car is back to normal, let see if the fuel pump will fail again in another year of time...

The story begins with a obd device for bmw, doing scanning is good, and I tried to do some service reset, it corrupted t...
12/07/2023

The story begins with a obd device for bmw, doing scanning is good, and I tried to do some service reset, it corrupted the data stored in the dashboard, everytime it shows service icon when the car start.

Unfortunately, even I tried to use the ista to reset, but failed.

What the heck, so I have to reflash the instrument cluster, perform coding again, then the problem is resolved.

To be honest, it is the first time I encountered data corruption error which need to do the programming to rectify the problem.

Luckily I got enough tools to fix my errors.

Now no more code, and looks so clean.

This is a fully toasted absorber, 0 damping power.
01/07/2023

This is a fully toasted absorber, 0 damping power.

This well maintained f20 has recently got a drivetrain error, which the owner said it can drive like a NA car, but don't...
30/06/2023

This well maintained f20 has recently got a drivetrain error, which the owner said it can drive like a NA car, but don't have turbo.

The engine is n13, and when the first time I scanned, it said the integrated power distribution shorted to ground.

Looks around the internet and people said after replacing the module, everything will be good. I then tested the module, the fuse 1 which is 15A is blown. I cannot replace the fuse, as it is soldered on the circuit board...

Then I immediately ordered a new integrated distribution module, and vola!, the fault is gone, and I tell the owner that the issue is fixed, and the turbo is back, no more error.

I do a quick test drive, I hear some abnormal idle for few seconds, and after restart the car seems okay again.

Then I started testing the turbo, the car runs strong with good acceleration.

And then after around 2-3 minutes, the drivetrain error comes on again in the middle of the test drive.

I pull over and stop the car, start again, the error stays there and the car is no more power again, idle is fine, no shaking, means not related to sparkplug or coil.

Then returning back to workshop and hook up computer, the same error again, fuse 1 is blown on the newly replaced module.

I removed the dme, checking the wiring diagram, the fuse 1 is responsible for 5 sensor, vanos in and out, blow off valve, mass air flow sensor and oil pressure regulator valve.

I start to guess there must be a sensor is failed and shorted to ground.

Unfortunately, all of the sensors ohm value are within specifications.

So I have my best guess that this time will be very high chance on dme failure.

The next day, I do the final check on dme pins, taking out and try to connect the positive to locate the sensor power pin, all good, and check if those are shorted to ground, which non of them are shorted to ground...

Now I am stucked because the dme seems okay, and all sensor reading seems okay...

Scratching my head... what is the root causing short to ground...

I then install the dme, and testing again, one pin to the power line of the blown fuse, another pin to the car ground.

It is definitely shorted to ground, as there is ohm value.

And then I try to remove the socket on dme one by one, found that only the short to ground situation is happening when socket 2 is connected to dme, referring to sensor that is connected to socket 2, it is the oil pressure regulator.

Rechecked the ohm reading of that sensor , it is good...

But wait, then I realized that I should also check the positive of the sensor to ground, found that the positive wire of oil pressure sensor is shorted to ground, although the valve fluctuate from 2 ohm to 100 ohm.

Finally identified that the root cause why the car blown the fuse, is due to the faulty pressure regulator solenoid.

Getting a brand new oil pressure regulator solenoid and test with ohm, the positive wire is NOT shorted to ground.

Unfortunately, with the n13 design, the parts is located inside the oil pan area, which need to remove oil pan to access that parts.

The remaining job is massive but straightforward, remove oil pan, which has to detach the entire subframe, hook the engine to install positions, and replace the good one.

I have to get another new integrated distribution module again as the one I just replace has fuse 1 blown.

Install everything back, do a half hour test drive, rev up to ensure turbo kicks in, good power, and no more error pops up again.

I perform a final computer scan, and everything is good as new.

Sometimes, troubleshooting is really a challenge but fun process. And the very good lesson learn this time is, I finally knows what is shorted to ground really means, even I heard this term a lot in the past.

Happy to see a car is back on her peak state again.

Finally the big rebuild project comes to the end, still have some minor noise to follow-up, but the efforts spent to re...
01/06/2023

Finally the big rebuild project comes to the end, still have some minor noise to follow-up, but the efforts spent to rebuild this car is enormous.

After the rebuild, as most of the parts in engine inside is new, after 300km mild driving to break-in the piston ring, the engine acceleration is very smooth, low-end torque is also very good, when comparing to before.

And the most important is, no single drops of oil leaks, abnormal for a bmw car.

During the MOT, the inspector chit chat with me that he never see a no car with age 2005, without single drops of oil underneath, that so funny.

Happy to see a car is back to her peak state again

This car is mercedes w204 c200 2013, equiped with m271.860 engine.Suddenly the owner reported that there is strange nois...
01/06/2023

This car is mercedes w204 c200 2013, equiped with m271.860 engine.

Suddenly the owner reported that there is strange noise happening during cold start.

He said it was Starter issue, while when I check, it is something more serious...

The noise is coming from cam adjuster, in bmw terms, it is called vanos.

Checking online, the Mercedes have issue with the car before 2013, and afterward, an updated design is used to avoid easy breaking of the cam adjuster.

Once I got the confirmation to refresh everything I see necessary, I ordered all the equipment, do the proper installation with proper spec, looking up the wis, found that only this m271.860 required 130nm of torque, while the other or all information say is only require 90nm, lucky I do verify the information before installing the valve cover, or else eventually the bolt is not tight enough which will lead to engine damage.

Assemble it bit by bit, takes long time but the journey is rewarding.

After everything is done and do the quick spin, the throttle response and acceleration is very solid, guess it is because of replacement of the cam adjuster, the timing is very accurate and the car drive far more smoother then before.

Nice to see a car is back to her peak state again.

＃Mercedes ＃w204

After several months of lazy bit by bit working on the engine rebuild project, finally reaching to the most nervous par...
27/04/2023

After several months of lazy bit by bit working on the engine rebuild project, finally reaching to the most nervous part of the project, first start of a fully rebuild engine.

The whole journey is real fun and to be honest, I learned a lot of technical knowledge via doing this project, as well as the improvements on the mental calmness

Since it is the first time that I break the whole engine apart, I have to ensure every single step is doing properly and using correct torque spec, proper screw material, proper gasket, fix the broken pcs, etc.

If I had of any uncertainty, I will lookup the internet, to clear any misunderstanding before I move on the next step. However, the more i read, and found that there are quite a lot of wrong info from YouTube, as those diyer are somehow having the wrong approach, and i have to verify against with bmw documentation, which is the primary cause why taking so long to do the rebuild.

And the more I read, the more I appreciate how those mechanical engineers invent such engine designs, which is very precise and creative.

A lot of people loves car in Hong Kong, but moving forward to rebuild the engine is probably quite a few, I am glad that I have a chance and courage to mess with it.

Today the first start attempt, i can regard as a perfect start of the engine.

And to start the freshly rebuild engine, alot of things have to take care, like connecting all the wiring harness, attaching coolant hose back, and most importantly is the priming of the engine oil pressure. Normal garage just teach me simply do cranking and if lucky, after 1 to 2 minutes can start as engine oil pump circuit contains a lot of air after rebuild, which require to push out before it can start.

While this statement makes me confuse and then I got a official document from bmw, which teach me to remove the fuel injectors connector and perform the crank for less than 10 seconds, for 2 to 3 times, and there must be at least 20 seconds gap in between to allow the Starter to cooldown. By which, we can ensure no single drops of fuel are entering the cylinder that might causing too rich conditions, that will affect the air fuel ratio, this making it harder to start.

For me, I added a personal step, to remove the sparkplug during the prime, which will lower the cranking resistance of engine due to no need to build up the pressure, thus fast oil pump speed that helps faster to remove the air inside engine.

A lot of minor details revealed how those engineer design and write the guidelines.

We are here to learn, and we are here to growth.

Happy to see my car is going back to road in the foreseeable future, finally

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Sai Kung, N. T
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