Banjo bolt lying in the valve train

[Kibokojoe]

Decided to adjust the valves in the sons 735i, M30 engine. Took the valve cover off and discovered one of the banjo bolts had worked itself out. Found it lying on the top of the head. Only found one of the aluminum washers. I am guessing the other one had fallen down one of the oil ports. Hopefully this will not cause any damage. The engine was making some valve clattering, I guess this may have been caused by the missing banjo bolt and improper oiling of the rocker arms and cam. Will need to order new banjo bolts and washers. Need to get the bolts that can be wire tied in place. Only two of the valves needed adjustment and both of these were just a little tight.

Decided to polish the valve covers with the Caswell aluminum kit


Before

http://i273.photobucket.com/albums/jj225/kibokojoe/DSCF1339.jpg

After: Started with 220 grit then 600 wet sanding along the way. Must keep your water clean.
http://i273.photobucket.com/albums/jj225/kibokojoe/DSCF1338.jpg

http://i273.photobucket.com/albums/jj225/kibokojoe/DSCF1355.jpg

[shogun]

How can I send you my head covers for the super polish :D

Think about a colating with something, otherwise they get darker again.
Maybe you try Alodine
http://www.aircraftspruce.com/catalog/cspages/alodine1201.php
http://www.eaa1000.av.org/technicl/corrosion/alodine.htm
http://www.auf.asn.au/scratchbuilder/alodine1201.pdf
If you do not use up the bottles, send them to me :)
I will share the cost, cannot get the stuff here.
http://www.eng-tips.com/viewthread.cfm?qid=168093&page=3

and now to the banjo bolts:
Gale's solution http://www.nmia.com/~dgnrg/banjo.htm

here is a new business for you ;)
Make these, someone from the German E31 8 series forum is making them for the German community. Looks nice.
http://www.7-forum.com/forum/5/nockenwellenschmierung-schraubensicherung-108140.html

[Kibokojoe]

If I make these locking washers can I reuse the banjo bolts? The washers look like copper? or are they aluminum?

[Kibokojoe]

What temperatures can Alodine handle?

[shogun]

http://www.henkelna.com/us/content_data/lt4958alodineec2electroceramiccoatings.pdf
http://www.henkelaero.com/Images/Datasheet_PDF/hst_alodine1200s.pdf
I guess the washers are made of copper, like the copper washers on banjo bolts on the powr steering pump.

Alodine is used by some people already, here some more info
http://www.aircraftspruce.com/catalog/cspages/alumprepaint.php
you need aluprep also
http://www.wicksaircraft.com/catalog/product_search_results.php/search=YWxvZGluZQ==
Alodine (Conversion Coating)


Chromate Conversion (aka Alodine® or Iridite®) is a chemical treatment process for aluminum used to provide corrosion protection and surface preparation for paint and adhesives.
Chromate is an excellent treatment method for paint or adhesives since it greatly enhances the product's ability to form a bond with the aluminum. It is frequently used on electrical and electronic equipment because it provides increased corrosion resistance while remaining electrically conductive.
The oxide films produced by this process vary in color, depending on the aluminum alloy being treated, surface conditions, and the type of chromate.

Key Benefits

1. Alodine resists corrosion.
Our test results on 6061 aluminum indicated that the Alodine treated surface withstood corrosion in a five percent salt spray test for 168 hours. Results do vary depending on the alloy of the material and the surface finish. We recommend that you submit a sample of the alloy and a description of the finish you intend to use. It will be processed and returned to you for evaluation.

2. Alodine is an excellent paint base.
Since the coating is not applied electrically and can be applied quickly, Alodine is one of the most cost effective ways to provide a suitable primer base prior to applying Paint.

3. Alodine is decorative.
Alodine has a light gold to dark gold appearance depending on your individual preferences.

http://www.poly-metal.com/alodine.shtml

[632 Regal]

locking washers will leak oil pressure.


If I make these locking washers can I reuse the banjo bolts? The washers look like copper? or are they aluminum?

[Kibokojoe]

Look at these locking washer. I am not talking about a split ring

http://www.7-forum.com/forum/5/nocke...ng-108140.html

[shogun]

locking washers will leak oil pressure.

No , Sir, they are standard
http://bmwfans.info/original/E32/Lim/735i-M30/USA/L/A/1991/01/mg-11/ill-11_1188/
see item 8
07 Hollow bolt 2 3,00 € 11 42 1 738 621
08 Gasket ring A8X11,5 4 0,11 € 11 42 1 252 343

[Ross]

BMW sells a replacement bolt that doesn't fall out. The heads have different markings, someone will no doubt chime in with the specifics about identifying them.
This should help http://www.bimmernut.com/forum/showthread.php?t=4546&highlight=banjo+bolt

[Bill R.]

Look at these locking washer. I am not talking about a split ring

http://www.7-forum.com/forum/5/nocke...ng-108140.html


Must be just me but it won't let me look at the images unless i register...
At any rate the new style bolts with the factory encapsulated loctite type coating on them work fine as well as Don Gale's safety wire solution for a very good price... If your bolt has been backed out for awhile and it was the front 2 valves that were loose and tapping you better look at the cam lobes to see if they have gone flat or worn considerably. I've seen it on a number of m30's over the years.

[Kibokojoe]

Ended up making my own locking bracket out of 0.032 brass plate. After I saw the picture of the ones made in Germany it was pretty easy. All I had to do besides the bracket was to make some compression washers out of aluminum on my lathe, that was pretty easy too. The thickness of the new washers and the brackets equals the thickness of the original washer. Didn't want anything obstructing those oil orifices. Anyway I have installed the banjo's, washers and brackets with high temp locktite. Torqued them to 96 inch pounds. I have looked at the cams on the shaft and there is no noticeable wear or flat spots. Thank God. Must have just happened. I will wait for my son to get home to finish the rest. Should have it back on the road by tomorrow.. Maybe tomorrow I will pull my 535i in the garage and fix the banjo's on her. :) If anyone is interested I will post the dimension of the bracket. Not real difficult to make and you can be off a little and it will still fit nicely.
http://i273.photobucket.com/albums/jj225/kibokojoe/bracketforbanjobolt.jpg

http://i273.photobucket.com/albums/jj225/kibokojoe/bracketforbanjoboltmounted.jpg

http://i273.photobucket.com/albums/jj225/kibokojoe/bracketforbanjoboltsidephoto.jpg

http://www.henkelna.com/us/content_data/lt4958alodineec2electroceramiccoatings.pdf
http://www.henkelaero.com/Images/Datasheet_PDF/hst_alodine1200s.pdf
I guess the washers are made of copper, like the copper washers on banjo bolts on the powr steering pump.

Alodine is used by some people already, here some more info
http://www.aircraftspruce.com/catalog/cspages/alumprepaint.php
you need aluprep also
http://www.wicksaircraft.com/catalog/product_search_results.php/search=YWxvZGluZQ==
Alodine (Conversion Coating)


Chromate Conversion (aka Alodine® or Iridite®) is a chemical treatment process for aluminum used to provide corrosion protection and surface preparation for paint and adhesives.
Chromate is an excellent treatment method for paint or adhesives since it greatly enhances the product's ability to form a bond with the aluminum. It is frequently used on electrical and electronic equipment because it provides increased corrosion resistance while remaining electrically conductive.
The oxide films produced by this process vary in color, depending on the aluminum alloy being treated, surface conditions, and the type of chromate.

Key Benefits

1. Alodine resists corrosion.
Our test results on 6061 aluminum indicated that the Alodine treated surface withstood corrosion in a five percent salt spray test for 168 hours. Results do vary depending on the alloy of the material and the surface finish. We recommend that you submit a sample of the alloy and a description of the finish you intend to use. It will be processed and returned to you for evaluation.

2. Alodine is an excellent paint base.
Since the coating is not applied electrically and can be applied quickly, Alodine is one of the most cost effective ways to provide a suitable primer base prior to applying Paint.

3. Alodine is decorative.
Alodine has a light gold to dark gold appearance depending on your individual preferences.

http://www.poly-metal.com/alodine.shtml

[Jeff N.]

+1 for Don's bolts. Install and forget.

And, they look cool.

[Kibokojoe]

Found some exhaust manifold satin clear coating and covered them tonight. Put the cover in the oven at 250 degrees F for 30 minutes. Will install them tomorrow. Looks pretty good really. They say it will handle up to 2000 F so I guess I don't have to worry about the coating burning off. :)

How can I send you my head covers for the super polish :D

Think about a colating with something, otherwise they get darker again.
Maybe you try Alodine
http://www.aircraftspruce.com/catalog/cspages/alodine1201.php
http://www.eaa1000.av.org/technicl/corrosion/alodine.htm
http://www.auf.asn.au/scratchbuilder/alodine1201.pdf
If you do not use up the bottles, send them to me :)
I will share the cost, cannot get the stuff here.
http://www.eng-tips.com/viewthread.cfm?qid=168093&page=3

and now to the banjo bolts:
Gale's solution http://www.nmia.com/~dgnrg/banjo.htm

here is a new business for you ;)
Make these, someone from the German E31 8 series forum is making them for the German community. Looks nice.
http://www.7-forum.com/forum/5/nockenwellenschmierung-schraubensicherung-108140.html

[shogun]

would be nice if you could give us the dimensions, so easy to make DIY.

[shogun]

wow, add the dimensions in millimeters and I can post in on the German board too
http://www.onlineconversion.com/length_common.htm
and it should mention:
dimensions in inch, mm
(maybe a remark on the side on an empty space):
dimensions in brackets = mm)
so no need to add always mm or millimeter

[shogun]

That is fine and usable. 8 mm for example should do then for 0.320 for example.
Thanks , I will link it then there too.

[Kibokojoe]

Made the change to (8.0). Anything else?
http://i273.photobucket.com/albums/jj225/kibokojoe/banjoboltbracketdrawing4.jpg

[shogun]

Perfect. That should do. Thanks

[Dash01]

Wasn't somebody just drilling a small hole in each banjo bolt, and then putting safety wire on to hold it tight?

Nice as Don's brackets are, wouldn't safety wire be a lot easier?

[Jeff N.]

Contact Don Gale. He has a kit of predrilled banjo's. Nice stuff.


Wasn't somebody just drilling a small hole in each banjo bolt, and then putting safety wire on to hold it tight?

Nice as Don's brackets are, wouldn't safety wire be a lot easier?

[Kibokojoe]

Sure but I didn't want to wait for the bolts and I had a half hour to waste :). Cost me about 50 cents to make. Either way you have to restrain the bolt or it will eventually spin back out. As my son he is dealing with a flat spot on the cam :(

[Dash01]

Contact Don Gale. He has a kit of predrilled banjo's. Nice stuff.


How does he drill them? Crossways through the head?

I have a drill press, cutting oil, and small hard bits.

[shogun]

Joe, do you still have some of these brackets?

[Grantus]

I cant see them either unless I register.

[Kibokojoe]

Nope sold the last ones. All I have is the drawing

[Kibokojoe]

http://i273.photobucket.com/albums/jj225/kibokojoe/banjoboltbracketdrawing4.jpg

[632 Regal]

Register then, significant other keeping you away?