Assembly

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Forged engine and engine bay repaint
Replace the piston-damaged engine with a machined 1999 T5 block, forged pistons and H-beam rods, and repaint the engine bay in Volvo 477.
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Plan
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Parts
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Gallery
Decisions & Unknowns
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Use a 1999 81mm-bore T5 block with factory crankcase windows. Match the bores to 81.2mm RSI-spec Wiseco pistons.
Tasks
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Remove the damaged engine. Strip, sand, prime, basecoat and clearcoat the engine bay in Volvo 477 Electric Silver Metallic.
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Machine and assemble with H-beam rods, King bearings, ARP2000 rod bolts and new OE head bolts.
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Install the head, sump and timing components. Refinish engine bay parts with fresh powdercoat.
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Weld redundant firewall panel holes, add reflective heat barrier and finish the front light harness with Deutsch connectors.
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Install the engine, revise the shifter to an E60 535i lever and fix the water pipe O-ring leak. Begin break-in driving with varied RPM.