E30 from Ukraine - "Shadow of Intelligence"

[The_Glory]

Just a photo

There's nothing to write about yet, so - just a photo :)
I took down the awning, but there's still a lot of dust under it... I'll have to do something with this "temporary" sand floor in the garage... I wiped it down, washed it a little - it's beautiful! ;)















Externally, the car is almost completely assembled. Only the front and rear bumpers remain to be installed. The mounting is all ready, the plastic bumper moldings are also ready for painting.
The repair kits and brake caliper parts have all arrived, all that is needed is to galvanize or paint the calipers.

Painting is a thing, not very cheap, and for me this year, with this war, the "financial collapse" has probably already reached its peak (or maybe it hasn't yet...), so this process will take a bit longer... I'm waiting.

[The_Glory]

Assembly_187. ETK_36_Steel wheel, design 1

According to my assembly plan, the last items in it were bumpers and wheels. The brake calipers somehow fell out of the plan - they should have already been installed, but something went a little wrong.. :) Now I'm working on bumpers, but in parallel I decided to pay some attention to the wheels. Although not all of them, but only the spare.
So, we will talk about the standard spare wheel. In all the time I had to use it no more than 2-3 times. Therefore, I decided to make it more like a "decorative" than a spare emergency wheel. :)

I'm starting the ETK section
Wheels with tires

The first section
Steel wheel rim, design 1




Maybe someday I'll buy a set of steel wheels with decorative caps for my collection, and for now I'm considering only one spare wheel. Before restyling, the steel wheels were silver, and after restyling, black. On early cars, there are silver steel wheels of "metric" size for TRX tires.

Part #1 - Steel wheel rim Silber 51/2JX14 ET:35 (36 11 1 125 686), Schwarz 51/2JX14 ET:35 (36 11 1 178 826), "metric" 365X150TD ET:35 (36 11 1 179 309). I have a narrower steel wheel Silber 5JX14 ET:35

Part No. 2 - tire valve L=42.5MM (36 12 1 116 326). When ordering this tire valve number, it comes complete with a spool and cap. Therefore, you do not have to order them separately.
Part #3 - valve spool (36 14 1 095 389)
Part #4 - valve cap (36 12 1 120 779)


In order to unscrew or screw in the spool, you will have to use an old cap with a special head. The original cap does not have one.

Valve assembly

Part #5 - Schwarz M12X1.5 wheel bolt (36 13 6 781 150). The original bolts have a black coating. I sandblasted and galvanized mine. When I get to the wheel kits, I'll probably buy a set of new bolts.

The following positions for the spare wheel, of course, I don't use, but I'll write them just for information.
Part No. 6 - decorative rim (36 13 1 120 543). Chrome-plated trim for the rim of a steel disc.
Part No. 7 - locking spring (36 13 1 122 301). Fastening the trim to the rim.
Part No. 8 - wheel hub cap (36 13 1 127 230). Chrome-plated decorative cap in the central hole of the disc.
Part No. 9 - emblem D=45MM (36 13 1 181 082). Sticker with an emblem on the cap.
Photo from the Internet:

Part No. 10 - wheel cap D=375MM for silver disc (36 13 1 178 778). wheel cap D=391MM for black disc (36 13 1 179 170). Photo from the Internet:

For the 318is and some Touring and Cabrio models, caps were available (36 13 1 180 667). Photo from the Internet:

Part #11 - emblem D=70MM (36 13 6 758 569). Sticker with the emblem on the cap.

To assemble the wheel, you also need balancing weights. Unfortunately, the "old-school" lead weights with the BMW brand have long been unavailable for order.
Balance weight, lead


So I ordered some new zinc weights. Unfortunately, they no longer have the BMW logo, so I could just install regular weights from a tire shop.
Zinc weight




Part #1 - locking spring for alloy wheel (36 11 6 766 311), or for steel wheel (36 11 6 766 312). Of course, I have it for steel wheel.
Part #2 - zinc weight. Different weight options are available. I ordered 4 pieces: 10G (36 11 6 766 315), 15G (36 11 6 766 316), 20G (36 11 6 766 317), 25G (36 11 6 766 318). By the way, the 10G weight is not zinc, but plastic. New technologies! :)

Part #3 is a zinc adhesive weight. These are modern weights. I haven't used them.

As I said, I decided to make an authentic spare wheel, although it will be more "decorative" than an emergency spare. I couldn't find the original BMW lead weights, but the tire is probably still original from the 80s, manufactured by MICHELIN. Of course, it's full of small cracks, it's scary to drive on it... I hope I don't have to! :) You should have seen the expression on the tire fitter's face when I showed him this tire and asked him to install it on the rim! )))
So, the rim was sanded, leveled, and powder-coated. They put the tire on, and there was a whole story about balancing it - namely, installing the weights. Apparently, the craftsmen were already used to gluing them, so there were some difficulties. :) But in the end, the wheel was assembled. It turned out so beautifully! ;)




Made in W. Germany


MICHELIN XZX


Old tire size marking - 175SR14






There is no modern marking of the production date on the tire. It would be interesting to find out the production date, but I don't know how...
The wheel looks nice and "old school" on the outside! ;)




I tried it on the car - it's cool too! :) Maybe I'll buy a set of steel wheels later ;)






But, its place is in the trunk.


Fix with a cap and nut.


Put a plastic support for the trunk floor trim.


Put the trim.


By the way, I already wrote in the relevant section on trim - usually the fixing cap has a slot so that there is no need to completely unscrew the nut to remove it and remove the wheel. But I installed an earlier cover, without a slot - to remove it and pull out the wheel, you need to completely unscrew the nut. We are not looking for easy ways! )))


We close the trim. Now the trunk is completely complete.


P.S.
Finally, I installed the moldings on the BBS pads. I had to file the lower edge of the molding a little.




So, all that remains to be installed on the outside is the bumpers. Now I'm preparing them for painting.

P.P.S.
I ordered repair kits for brake calipers. But they need to be cleaned and painted. I'm considering three options:
1 - electroplating. Complete and uniform cleaning and coating. Simple, reliable and not expensive.
2 - powder coating. Better appearance, but the problem with the threaded holes and inner surfaces of the cylinders - they will remain uncoated.
3 - ceramic coating. Beautiful appearance, but the same problems as with powder coating. A little more expensive.

If anyone has already done any of these options, I would appreciate feedback and recommendations.

[The_Glory]

Assembly_186. ETK_61_Wiper lever / wiper blade

I was going to order wiper blades for a long time, but I kept forgetting about them. And finally, when I was ordering a belt for the power steering pump, I somehow accidentally remembered about the brushes! :) I ordered it. So, the pump works fine, the system was shaking, everything is OK. Therefore, I return to the ETK section
General electrical equipment of the car

Its last subsection
Wiper arm / blade wiper





Original wipers can be from two manufacturers - SWF or BOSCH.

Part No. 1 - left wiper arm (61 61 1 372 551) and right (61 61 1 372 552) - 2 pcs. In my case, these are BOSCH arms - left 66577 and right 66578. The left arm has a greater bend in two planes, and a shorter length than the right one.





SWF levers differ from BOSCH in a shorter spring and the absence of a rivet on the body.

In the photo, black - SWF, gray - BOSCH. By the way, I do not advise clicking with a spring on the removed lever - I broke the lever mounting bracket like that. Then I accidentally bought a SWF lever, and realized that they are different :) I had to look for a BOSCH lever.
Part No. 2 - left wiper blade (61 62 7 140 965) and right (61 61 8 353 297), or a set of brushes (61 61 9 069 196) - 2 pcs. In the original, SWF brushes are most often used. I ordered them by the number of the analogue SWF 116112, - so much cheaper.


The brushes have a replacement schedule indicator - a black circle near the brush mount. When the circle turns yellow - the brushes need to be replaced.

The brushes need to be installed with this circle facing up so that it is visible.

Part #3 - rubber element of the wiper blade (61 61 1 372 747) - 2 pcs. You can replace only the rubber insert itself, but I'm not sure if this makes sense.
Part #4 - protective cap SWF (61 61 1 372 746), or BOSCH (61 61 1 376 313) - 2 pcs. In my case SWF.


Install and snap the blades onto the lever.


We put the levers on the axis of the wiper mechanism, align them and tighten them with a nut.


We insert a protective cap under the lever and close the nut with it.


The wiper blades are installed.




Close the hood - done.






So, on the outside, all I had to do was paint and install the front and rear bumpers. Technically, - restore and install brake calipers. I'm working on it.
The finish line is coming soon! :)

P.S.
I still need to fix at least one set of wheel disks. I've already started a little, I'll write about it next time.

[The_Glory]

Assembly_185. ETK_32_Power steering pump. (continued)

I will remind you that last time the installation of the power steering pump was stopped for this reason - a gap of 1 mm between the pulley and the radiator drain plug.


Installing thin washers and flat-head bolts did not solve the problem - the gain on the bolts was only 2 mm, but the pump axis remained in the same place. There is no place to move the radiator either - it is already close to the body. So, the only option left was to move the pump. It was not possible to move it up, because it rested against the generator. Therefore, you only need to move it down. And then new problems appeared - a short tension bar, a belt and a hose from the tank.
For the tension bar, I made an "extension" and screwed it with a bolt.




I wanted to screw it with two bolts, but the second bolt interfered with tensioning, so I left one. Thanks to the sides on the bar, the plate is fixed well with one bolt.
I ordered a hose for the tank for the third time :)
I measured the length of the belt with a rope and calculated it using some formulas :) I calculated 838mm. The standard is 825mm. The difference of 13mm immediately seemed too small to me... but mathematics is an exact science! I ordered it.




The belt arrived, I tried it on - it's short! ))) The pump remained practically in the same place.
The second time I took measurements more accurately - with a rubber cord, with a similar cross-section to the belt. I fixed the pump in the desired position. It turned out 880mm. This is already something similar to reality. I found an 875mm belt. This time I decided to "save money" and buy the cheapest belt that was available at the local auto parts store - just for trying on. Suddenly it won't fit again... And it did! :)


Well, now I'm ordering a good belt - Continental AVX10x875. This is a generator belt for M10 and S14 engines. Now there will be at least one part under the hood that matches the VIN code of the car! :)
Belts in stock! :)


By the way, the cheap 10x875 belt, judging by the inscription on the package, is for the engine of the AZLK "Moskvich" car! It's probably no coincidence that that engine looks so similar to the BMW M10 engine! ;)


So, I install a new belt, tighten it and fix it on the bar with an extension.


I screw the longer hose from the tank, and the high-pressure hose to the steering rack. The pump is installed.


Now the gap between the pulley and the radiator drain plug is a little more than 1 cm. I think this is quite enough.




But now the pump is very low - level with the engine oil pan.




Maybe it's not very good, but it's not critical - the main thing is not lower!
I tried on a protective plastic shield - it gets right up to the pump, but covers it.


The restyled air conditioning panel has special ventilation holes - they are located almost under the pump.




The pump is closed.


I will install an early plastic panel that does not have ventilation holes. I was going to cut them in the same place, but it's a good thing I didn't have time to cut them. Now I'll move them a few centimeters so they're exactly under the pulley so it doesn't rub against the shield.
But I'll install the shield later, after I install the air conditioning compressor. I think everything will be fine.

[The_Glory]

Assembly_185. ETK_32_Power steering pump

So, let's move on to the last section of the ETK on steering:
Power steering pump


Finally, I bought a new power steering pump. I'm not sure if this pump is really new, most likely it was refurbished at the factory. I chose the manufacturer Meyle, although in fact, in appearance this pump is no different from similar cheaper options.






But it looks pretty good. I hope it works well. )




120bar declared. The original pump was 110bar. Let's see how it pumps...


Now I decided to change the tank too. I put it new once, but that was a long time ago. The tank has a built-in filter, so it's better to replace it. I chose the Febi tank.




The lid shows the ETK number (83 29 0 429 576) - Hydraulic fluid CHF 11 S. That is, the tank for Pentosin lubricant.


The lid is ordinary.


The filter looks similar to the one in the old ZF tank for ATF lubricant.


I bought a new hose for the tank again because I lost it somewhere, I don't know where it went.


Since I use ATF, I installed the old cap on the new tank so that there would be no confusion with the lubricants )


The tanks look the same.


I already wrote about installing the tank and hoses, so I just replaced the old hose and tank with a new one.




New tank with old cap for ATF


Back to the pump. The kit included a mounting bracket, most likely for the E36. I also wrote about the mounting brackets earlier, they are already installed on the engine. But two brackets need to be installed on the pump.


Unscrew the fasteners that were included in the kit and install one bracket in the following position:


On the other hand, screw the second bracket:


The pump is ready for installation.


Power steering pump installation kit:


Part #1 - power steering pump 110BAR (32 41 1 133 969). I use a Meyle pump (314 631 0001) 120BAR


Part #2 - pulley (32 42 1 730 371) - 1 pc.
Part #3 - bolt M8X12 (07 11 9 913 616) - 3 pcs.
Part No. 4 - spacer washer A8.4 (07 11 9 900 052) - 3 pcs.

Part #5 - V-belt 9.5X825 (32 42 1 706 5970 - 1 pc. I use a Continental AVX10x825 belt

Part #6 - repair kit for ZF pump (32 41 1 135 880), or VICKERS pump (32 41 1 133 023). My original ZF pump was very worn out and could not be repaired. Therefore, it was replaced with a new one.

We fasten the pulley to the pump with three bolts.


I also wrote about the hoses earlier. It remains to screw two fittings to the pump. The thread diameter in them is different, so the inlet and outlet hoses are physically impossible to mix up.


We fasten the pump with two bolts to the brackets on the engine. We put on the belt.


An additional double pulley for the power steering pump and air conditioning compressor is already installed on the motor pulley. The front pulley is used for the power steering pump.

We tighten the belt using a special bolt and gear and fix it with a nut. Then we tighten the other bolts of the pump and the tensioning bar.


We screw the supply hose fitting from the tank, and the high-pressure hose fitting to the steering rack.


The power steering pump is installed. You can fill in ATF and bleed the system.


BUT there is one nuance!
Here is such a gap between the bolts of the pump pulley and the radiator drain plug...


A large radiator with a built-in expansion tank from the M40/M42 turned out to be great. But, only now it turned out that its drain plug was right opposite the pulley! It's scary to leave it like that - so that the pulley does not break the plug when the engine vibrates. And what to do now - I don't know ... I have one idea, but if it works out, I'll write about it next time.
On this "optimistic" note, the installation of the power steering pump is stopped! :)

[The_Glory]

New Year's gifts

I didn't do anything to the car during the holidays, so I'll write about "gifts" for myself and my "thirty"! :)

By the way, before the New Year I met such a cool "New Year's" E30 - with a Christmas tree on the roof and garlands! ))


In the evening of December 31, I arrived home, and in front of the gate is a set of wheels with MIM 1900 rims!




I received such an unexpected New Year's gift from a neighbor who was raking through old junk in his garage! :) Once these wheels were on an Alfa Romeo, regardless of the fact that there is a PCD of 4x98 ) And for the last 15 years they have been lying in the garage. MIM 1900 wheels with parameters specifically for the E30 - 7J15 ET13 PCD 4x100. Although, I don't really need them, because I already have three sets of wheels, but I decided to take them anyway - let them be! Especially since the price was symbolic, really - a gift! ;)


Of course, there are scratches on the rim, but the overall condition of the rims is good. I tried them on - they look good! )


But the 205/55 tires are too wide! )


My OZ rims with similar parameters and 195/60 tires in width are getting better.




So, for the holidays I covered the car with an awning so that it would get less dust.


And off I went to celebrate! :))


And after the New Year, two more "gifts" arrived - two boxes for cassettes with vertical boxes.


Surprisingly, both are completely intact and in working order!




I've mentioned them before, and I'll write more about them later.

P.S.
There's also news about the assembly, but there are no major problems with the power steering pump. I'll write about that next time.

[The_Glory]

Assembly_184_Additional BSC options - OVERHEAT

I have long written about the fact that I installed a top-of-the-line on-board control system unit for the Japanese market, with four additional options, and added wires for them to the interior wiring harness. I will not repeat myself about this.


Now it is time to fully complete their functionality.
Now we will talk about an additional option that was available only for the Japanese market - OVERHEAT. This lamp signals overheating of the catalyst. For this, it has a temperature sensor and a special relay. I have not had the catalyst for a long time, respectively, and there is no point in looking for that sensor and relay.
Therefore, I decided to use this lamp differently - connect it to the temperature sensor, which at a temperature of 99 degrees turns on the air conditioner fan at second speed. That is, the lamp will warn in advance about possible engine overheating. I also wrote earlier that I added an additional button to the fan wiring diagram for manually turning on the second speed. I connected the button to the corresponding contacts in the fuse block. And the wire from the lamp, without thinking at the time, was laid all the way to the sensor on the radiator. Now I realized that it was useless - it would be logical to connect it to the same contacts as the button. But there is a nuance. The relay (K6) of the second fan speed is activated by the "plus" of the power supply, and the additional lamps of the on-board control system are activated by the "ground". So, I had to install an additional relay that converts the "plus" to the "ground". I drew the connection diagram of the button and the relay on the diagram of the ETM electric fan.


Connect pin 86 to the button connector that goes to pin 86 of relay K6. Connect pins 30 and 85 to ground at point G104 behind the left headlight. Connect pin 87 to the OVERHEAT lamp wire.


Install the yellow relay in the standard relay location on the fuse block.


This is a regular relay, the same as all the orange relays in the fuse block. I just had yellow. They are also orange or brown. Yellow is the prettiest! :)


Now, when you manually turn on the second speed of the air conditioner fan in the cabin, the green button and the OVERHEAT lamp of the on-board control system light up.




If the coolant temperature reaches 99 degrees, the OVERHEAT lamp will turn on the temperature sensor together with the fan. In this case, the button will not light up.
Everything seems to be logical, useful and convenient!
In my opinion, this functionality of this lamp is even more useful than the standard Japanese one! ;)

P.S.
If anyone noticed, there is another additional purple relay installed in the fuse block - K9. I have also already mentioned it in the relevant section about relays, but I will repeat it again. This is a relay that, when the high beam is turned on, automatically turns off the rear fog lights, if they were on. This option was available for the French and Swiss markets. Probably because there is often fog there. On other cars, instead of a relay, there is a metal jumper. I don't understand why this relay was not installed as standard on all cars. After all, it is logical - a normal driver will not turn on the high beam in the fog. And if it turns on, then it is logical that there is no more fog, so the rear fog lights can be automatically turned off (if the driver forgot to do it himself) so as not to blind the bright red light of drivers driving behind. I am even more surprised by the complete absence of rear fog lights for the US market, especially given that there were stricter safety requirements than in Europe. Strange.
So, I consider this a useful option that is very easy to install. Just remove the metal jumper and put a purple 5-pin relay in its place. The same relay is used as the comfort relay for power windows.

Sometime later I will write about another additional lamp of the on-board control system - the driver's seat belt. And so far it is not working for me yet.

[The_Glory]

Congrats on the first start! It's been an impressive journey

Thank you!
It doesn't seem like there's much left, but with this war, the further it goes, the harder it gets... I'd like to finish it by spring so the car can finally drive, but I'm not so sure about that anymore...

[Northern]

Congrats on the first start! It's been an impressive journey

[The_Glory]

Outstanding! Congratulations - nothing like the feeling of that first start.

Thank you! I completely agree!

[The_Glory]

That is looking so good!!

you are genius!

Thanks)

[mjweimer]

Outstanding! Congratulations - nothing like the feeling of that first start.

[Mazi!]

That is looking so good!!

you are genius!

[The_Glory]

Congratulations!!!

That "ha!" you said when the car started is heartwarming and familiar to any car person.

Thank you! I am really happy! )

[roguetoaster]

Congratulations!!!

That "ha!" you said when the car started is heartwarming and familiar to any car person.