Okay, finally got some progress to report.
Got a G.A.S DISA repair kit, glad the DISA in the bad engine was a BMW OE unit and the diaphragm was holding vacuum.
As others have noted the GAS kit is well made, very high quality. I went with a Viton o-ring, for a few cents more, why not:
https://lh3.googleusercontent.com/HF...Y=w678-h509-no
The old DISA was just flopping around, the plastic socket of the flap was rounded out:
https://lh3.googleusercontent.com/Yw...I=w530-h706-no
All done, probably took 30-45 minutes working slowly (and getting distracted by text messages):
https://lh3.googleusercontent.com/ea...A=w530-h706-no
Next up, I noticed the intake manifold had a plug and o-ring seal. It goes between the runners for cylinders 3-4. I guess the earlier cars (maybe < 03/'01) had intake temperature sensor that plugs in and this plug just seals up the port. I thought I'd replace the o-ring, who knows maybe it was compression set and leaking? Probably not, but now I have more confidence in it. The o-ring is cheap (8x3, PN: 13-62-1-743-299).
New one is 8mm ID x 3mm. The old one measured about 2.67-2.72 mm (variance due to elasticity of material and the Harbor Freight caliper; good enough for this application):
https://lh3.googleusercontent.com/a5...A=w530-h706-no
Good as new:
https://lh3.googleusercontent.com/ie...c=w530-h706-no
Ok... onto the meat and potatoes (engine extraction). I had to disconnect the fuel lines, took the opportunity to replace the fuel filter. Glad I did, the old one looks to be original - date stamped "13 04 04" - and the mfg date of the car is 04/04. Oh well, new filter, and even a new used engine to go with it.
https://lh3.googleusercontent.com/fH...E=w194-h259-no
Link to video of black fuel pouring out of filter. That's original for sure.
...
Back to prep for engine extraction. Disconnect the transmission selector cable:
https://lh3.googleusercontent.com/WZ...I=w678-h509-no
Lots of road grime, will get a thorough cleaning before going back in.
Disconnect the other hoses, cables, brake lines and sensor.
Remove the exhaust. This thing is such a pain in the butt. One piece from header to exhaust tips, wth. I'm sure they saved a few bucks on nuts/bolts/gaskets. Pain in the butt. Good thing I had a couple extra jack stands to support the damned thing when unbolting. I really need to buy a lift. PB Blast on the header bolts/nuts for 30 minutes or so and it was relatively easy with a breaker bar. It's out:
https://lh3.googleusercontent.com/6E...Q=w530-h706-no
No action shots of the engine being pulled out, too busy doing it to take photos. I enlisted the help of my mom to hold the AC condenser and AC compressor (I didn't want to have the system recharged as that would be extra $$) while I pulled the engine/trans/subframe/front suspension out in one unit. I used a Harbor Freight transmission jack under the transmission (seems appropriate) and a HF engine hoist to the front lift point. Just wheeled it out. I forgot to disconnect the headlight level sensor from the control arm... and the arm of the sensor broke... doh! :facepalm. It is what it is.
...and it's out. Mom checking out our good work (gloves make her an official helper. :thumbsup lol):
https://lh3.googleusercontent.com/d5...8=w530-h706-no
This is a milestone. :applause2 Lots of good feelings (even with the broken sensor).
Driver's side of the transmission. This will be cleaned and the transmission filter and fluid will be changed.
https://lh3.googleusercontent.com/f1...I=w678-h509-no
Engine bay will be cleaned - have to eliminate the remnants of the rats. Hoses will be replaced, and electrical connectors will be cleaned with Electromotive or similar type of spray.
https://lh3.googleusercontent.com/Pv...k=w530-h706-no
The garage is full... I need to get these parts back on the car so I can park a car in here again:
https://lh3.googleusercontent.com/RV...Y=w530-h706-no
While the wheels were off I took them to Costco and got a set of Michelin PS4S at the end of 2018 when they had a great deal (it was like buy 3 get 1 free), they're under the work table.