E30 from Ukraine - "Shadow of Intelligence"

[The_Glory]

Your build looks so beautiful! слава україні! One question, how important is this damper? I'm restoring a 1988 4 door (building into a drift car), I have been away from the car for about decade, but do have two E30's worth of parts to a certain extent so it's been a lot of digging through bins I labeled long ago. Also have ordered half an M20's worth of parts from pelican from what was available. It's a 2.7L with a 325is head and Shrick 288 on MegaSquirt 3.0 with external Bosch mosfet's driving MSD GM 44kv coil packs in a wasted spark configuration, 42lbs Mustang injectors...

Thanks!
Героям слава!!
This damper is important for comfort. It dampens vibrations from the transmission. But how noticeable this effect is, I can't say, because I haven't had it before. I think that the difference is not significant. It is definitely not needed for motorsport - it is an extra one and a half kilograms of weight that needs to be rotated.
You have a cool sports specification!

[E30Eric]

Your build looks so beautiful! слава україні! One question, how important is this damper? I'm restoring a 1988 4 door (building into a drift car), I have been away from the car for about decade, but do have two E30's worth of parts to a certain extent so it's been a lot of digging through bins I labeled long ago. Also have ordered half an M20's worth of parts from pelican from what was available. It's a 2.7L with a 325is head and Shrick 288 on MegaSquirt 3.0 with external Bosch mosfet's driving MSD GM 44kv coil packs in a wasted spark configuration, 42lbs Mustang injectors...

[The_Glory]

Collection_152. ETK_26_Cardan shaft

It remains to prepare the cardan shaft.
Cardan shaft

Elastic coupling / intermediate support of the cardan shaft




Part #1 - centering sleeve (26 11 7 526 611) - 1 pc.
Part #2 - elastic coupling LK=78MM/D=110MM (26 11 1 225 624) - 1 pc.
Part No. 3 - damper of torsional vibrations (26 11 1 434 254) - 1 pc. After 1988. I will write a little more about him below.

Part #4 - bolt M10X50/10.9 (26 11 1 209 498) - 3 pcs.
Part No. 5 - bolt M10X50/10.9 (26 11 1 225 744) - 3 pcs. Or bolt #4. I had all the bolts the same.
Part No. 6 - spacer washer A10 (26 11 1 225 821) - 6 pcs.
Part No. 6 - elastic washer B10 (07 11 9 932 122) - 6 pcs.
Part No. 7 - M10 nut (07 12 9 964 672) - 6 pcs.
Part No. 8 - file (26 11 1 225 089) - 1 pc. I did not remove it from the cardan shaft.

Part #9 - radial bearing D=55/D=30 (26 12 1 225 071) - 1 pc.
Part No. 10 - intermediate support 55X13X30 (26 12 1 225 152) - 1 pc. Assembled with bearing No. 9. Analogue of SWAG 20870005.

Part No. 11 - file D=30X58X5.5-CRH (26 11 1 225 088) - 1 pc.
Part No. 12 - retaining ring (26 12 3 648 156) - 1 pc.
Part No. 13 (No. 15) - threaded ring with clamping ring (26117514037) - 1 pc. Collected from No. 15.
Part No. 14 - gear washer (26 11 1 209 285) - 1 pc.

Part No. 15 (No. 13) - threaded ring with clamping ring (26117514037) - 1 pc. Collected from No. 13. Analogue of SWAG 20926858.

Part No. 16 - screw M10X25 (26 11 1 206 718) - 4 pcs.
Part No. 17 - nut M10 (07 12 9 964 672) - 4 pcs.

Part No. 18 - bolt M8X22 (07 11 9 915 160) - 2 pcs.
Part No. 19 - a repair kit for cardan crosspieces with hinges.

There is no photo of the cardan shaft assembly. They collected it in a friend's garage - there was no time to take pictures. But it looks somewhere the same ;)
Cardan shaft / universal joint


Part No. 1 - cardan shaft of a 5-speed manual transmission (26 11 1 225 635).

The crosses are in good shape so I left them as they were.

Briefly on the assembly of the cardan shaft.
First, we change the centering sleeve No. 1. Although it was possible to leave the old one, but I decided to replace it. It turned out not to be so simple. It was possible to pull out the old sleeve only by hollowing out its rubber part and cutting a thread on it. We press a new one.
Then we press the bearing of the intermediate support No. 10 with the shoulder close to the file No. 8. We install file no. 11, fix it with locking ring no. 12. We put the ring No. 13 (No. 15) and toothed washer No. 14 on the shaft.
We connect both parts of the cardan shaft along the slots. When I took it apart, I marked the relative position of both parts. They collected it according to these marks. Otherwise, you will have to rebalance the gimbal. We tighten the threaded ring No. 13.
We insert the elastic coupling #2 into the damper #3 and fasten it to the cardan shaft with three bolts #4.
The cardan shaft is ready for installation.

But, in fact, it was not so simple! :)
As I wrote in the previous post, the gimbal rested on the short-stroke Z3M link, so I had to replace it with a standard one. And these are not all problems.
I didn't have damper #3 before. Since, according to ETK, it should be on the 325i model, I decided to install it. But with the Z3M backstage, of course, it was completely out of place. After replacing the scenes with a standard one, I had to get up. But again, no! He resisted the pull. Since the work was being done at my friend's garage, which had to be vacated quickly, there was no time to deal with it and look for other details. Therefore, they removed that damper and installed the cardan shaft without it, as it was before.
But I was wondering what the problem was, so now, I figured it out at least a little... at least theoretically! ;)

So, as I wrote in a previous post, the pull and clamp are different before '89 and after '89. Photo from the Internet.
An early clip shifts the traction to the side, thereby moving it away from the damper.


In addition, the early thrust (25 11 1 220 838) in the area of the damper has a special stamping, and axles of different lengths.


Perhaps this is exactly what allows you to install a damper.

The late drive (25 11 1 221 657) is straight, with axles of the same length as mine.


There is also a curved thrust (25 11 1 221 250), which according to ETK is applied to engines M40, M42 in E30, and to M50, M20 in E34.


There are also two types of dampers for the E30.
Until 1988 (23 13 1 222 514).


And after 1988 (26 11 1 434 254).


So, I have a post-89 bracket, a post-89 tie rod, a post-88 damper - everything fits... Why doesn't it fit?? :)
How to make this "puzzle"? If anyone knows, I would be grateful for tips. Later, when it may become completely boring, I will still try to install it... ;)

Next time, finally, I will write about the installation of the engine, gearbox with clutch, and cardan shaft.

[The_Glory]

Collection_151. ETK_25_Gearshift mechanism

The gearbox is ready for installation, but you still need to install the gear shifting mechanism on it.
Gear shift mechanism

Manual Gear Shift Mechanism




Part No. 1 (No. 2...No. 12) - gear shift lever (25 11 1 220 326) - 1 pc. The lever is assembled, and of course I did not disassemble it completely. Second lever (25 11 7 527 254) for Z3 M3.2. This is a more "sporty" short-stroke lever. But running ahead, I will say that it was not possible to install it - it rested on the gimbal. I don't know why, but somehow they put it on the E30... Maybe for this you need a cardan with a smaller diameter from the younger models. Therefore, it was necessary to replace it with a standard lever.

Part No. 13 - gear shift lever cover (25 11 1 220 204) - 1 pc. It comes complete with a plastic frame for its fastening. I have it sewn from a leather substitute. Maybe later I will order from genuine leather.


The design of the shift mechanism is significantly different before September 1985 and after September 1985. At the same time, on early versions of the manual transmission, there is no attachment for a later mechanism, and on late manual transmissions, both types of gear shifting mechanisms can be installed. In September 1989, minor changes were made to the design and mounting of the shifter linkage. In my case, this is the latest option, after 1989 - but I realized this only when I encountered some difficulties during installation. :)
Manual Gear Shift Mechanism




Part No. 1 - gearshift lever support frame (25 11 1 221 201) - 1 pc. It can be of different lengths for different motors and manual transmissions.
Part #2 - sleeve L=26MM (25 11 7 519 669) - 1 pc. Rubber sleeve.
Part No. 3 - support frame mounting axis D=10MMX40MM (25 11 1 221 849) - 1 pc.
Item No. 4 is not used.
Part No. 5 - terminal (25 11 1 220 837) - 1 pc. Plastic clip for fixing the wiring on the frame.
Part No. 6 - gear shift lever support (25 11 1 220 600) - 1 pc. Plastic sleeve.

Part No. 7 - casing (25 11 1 220 912) - 1 pc. Rubber lever cover.
Part No. 8 - hinged bracket for fastening the gear shift lever support frame (25 11 1 220 707) - 1 pc. A metal bracket with a rubber sleeve for rear frame mounting.
Part No. 9 - M8 nut (07 12 9 906 196) - 1 pc.

Part No. 10 - straight gear shift drive rod (25 11 1 221 657) - 1 pc. After 1989. For some reason, I have it boiled in the middle, it must have been shortened. They are of several types and of different lengths. It has some nuances, but I will write about them in the section on the cardan.
Part No. 11 - plastic washer 10X16X0.9 (25 11 1 220 439) - 2 pcs.
Part No. 12 - locking clip (25 11 7 571 899) - 1 pc.
Part No. 13 - gear selection rod clip (25 11 7 503 525) - 1 pc. After 1989.
Part No. 14 - ring of round cross-section 10X2.2 (25 11 1 221 243) - 2 pcs. Only until 1989. For the version after 1989, they are not used and do not physically fit on the axle. But I didn't know about it and I still put one ring in there! The second one didn't fit :)

Part No. 15 - spacer washer 16X10.2X0.65 (25 11 1 220 199) - 1 pc. For the version after 1989, washer #11 is used.
Part No. 16 - locking washer 8.0 (07 11 9 932 863) - 1 pc.

Part No. 17 - cylindrical pin (23 41 1 466 134) - 1 pc.
Part No. 18 - elastic sleeve (25 11 1 203 682) - 1 pc.
Part No. 19 - plastic washer (25 11 1 434 194) - 1 pc. Soft plastic insert.
Part No. 20 - reverse lamp switch wiring (23 14 1 220 263) - 1 pc.
Part No. 21 - terminal (61 13 8 364 037) - 1 pc. Metal clip for fixing the wiring on the manual transmission.

The rubber sleeve is pressed into the frame using a regular bolt with a nut.


We insert the lever into the pivot support No. 6. We click the support in frame No. 1, turning it clockwise. Lubricate the hinge. We put rubber cover No. 7 on the lever and pass wiring No. 20 through it. We fix the wiring on the frame with plastic clip No. 5. We install bracket No. 8 on the frame. The upper part of the mechanism is assembled.


In clip #13, there was a large artifact in the plastic sleeve. I ordered a new bushing from the turner and pressed it into the clamp.


We insert the soft insert No. 19 into the clip. The clip is fixed on the gear selection rod with a cylindrical pin #17. The pin is fixed with an elastic sleeve No. 18.


We install the clip on the No. 10 pull. We install the thrust on the lever.
Gear shift mechanism is fully assembled.




We install the clip on the gear selector rod and fix it with a pin.


We fix the pin with an elastic sleeve.


We insert the axle of the frame #3 into the body of the manual transmission and snap it into place. We put the metal clip No. 21 on the body of the manual transmission and fix the wiring in it. We connect the wiring to the reverse lamp switch.


The gear shifting mechanism is installed on the manual transmission.


Now the gearbox is completely ready for installation on the car.


It remains only to install the handle on the lever.
Before restyling, "round" handles were available in various versions.
Gear Knob / Covers / Emblems


Maybe one day I will buy such a handle for the collection, but for now I will have the handle installed after the restyling.
Gear Knob / Covers / Emblems




After the restyling, the handles were also available in many variants. In my case, it is a wooden handle - I already wrote about it in the section on decoration from valuable wood species.
Part No. 11 - wooden lever handle (25 11 1 221 674) - 1 pc.
Item No. 3 - 5-GANG/SCHWARZ sticker (25111221611) - 1 pc.


I also already wrote about the condition of the pen - it will be restored. The emblem will also be replaced by #8 (25 11 1 221 612) M-TECHNIK.
In addition, I want to make this pen with a light. In the original for the E30, such handles were only covered with leather. But I want to keep the wooden handle. That will be later.
Retrofit kit for manual transmission leather handle with illumination




Part No. 1, No. 3 - a complete set of retrofitting, no longer available for ordering.
Part No. 2 - leather manual transmission handle with M-TECHNIK illumination (25 11 2 231 551).
Part No. 4 - leather manual transmission handle with M-SPORT/5-GANG illumination (25 11 2 231 550).
Part No. 5 - wiring of the handle with illumination (61 10 2 230 890). I don't see the point of buying it, it's easier and cheaper to make it yourself. I have already installed it, and I wrote about it in the section on wiring the interior heater. It is connected there, parallel to the ashtray backlight lamp.


The connector is original.


So, the entire gearshift mechanism is ready for installation.

Then about the gimbal.

[The_Glory]

WOW! This engine looks like it came off from the factory line yesterday. Awesome job! Keep it up.

That enginebay looks like new!

Thanks, I really tried! )

[Mazi!]

That enginebay looks like new!

[MarkoEST]

WOW! This engine looks like it came off from the factory line yesterday. Awesome job! Keep it up.

[The_Glory]

Assembly_150. ETK_11_Engine. Engine suspension / damper


Engine suspension / damper



Part No. 1 - left support bracket (11 81 1 176 565) - 1 pc.
Part No. 2 (No. 5) - bolt M8X25 (07 11 9 913 653) - 4 pcs.
Part No. 3 - elastic washer B8 (07 11 9 932 095) - 8 pcs.
Part No. 4 - right support bracket (11 81 1 176 564) - 1 pc.
Part No. 5 (No. 2) - bolt M8X25 (07 11 9 913 653) - 4 pcs.
Item No. 6 is not used.
Part No. 7 - rubber-metal hinge (11 81 1 132 321) - 2 pcs.
Part #8 - nut M10 (07 11 9 915 558) - 4 pcs.
Part No. 9 - elastic washer B10 (07 11 9 932 122) - 2 pcs.
Part No. 10 - spacer washer A10.5 (07119904198) - 2 pcs.
Part No. 11 - thermal insulation screen (11 81 1 127 4930 - 1 pc.

Part No. 12 - stop (11 81 1 133 377) - 2 pcs. 1 pc is specified in ETK. But there, in the notes to detail No. 7, 2 pcs. I ordered two.
I waited almost a month for these stands under the engine pillows! Finally, they have arrived, and it is possible to complete the assembly of the motor before installing it in the car.




We screw the support brackets to the engine block.
Left


rights


Now, finally, the engine is completely ready for installation in the car! I will install it in this form.










I like it - beautiful! ;)

However, it is necessary to install supports.
I don't really understand the function of these parts (#12), but they are called "stops". What and how they support, I do not understand - the pillow becomes free in them, and they do not support it in any way.


Maybe it's heat protection and only one is installed on the right side...? It's not clear... that's probably why almost no one has them... some kind of "extra" detail, and it's not cheap either :) But it's not for nothing that I've been waiting for them for almost a month, so I'll put them on both sides! :)


Left


rights


A thermal shield (No. 11) is also installed on the right side from above. I didn't have it before either.


The entire set of regular thermal protection.


I disassembled the front part again :) Thoroughly washed the entire engine compartment from dust and prepared everything for engine installation.






I will install it soon.

[The_Glory]

Collection_149. ETK_11_Engine. Cooling system water hose

For 1985 it should look like this:
Cooling system water hose


But on my car, the entire cooling system was installed with an E34 M20B25. Including a radiator with a built-in expansion tank. Its lower fastening was self-made. Now I have the stock restyling mount installed, and accordingly, the radiator will be fixed with the stock mount. The radiator will be larger, for the air conditioner. So I see no point in going back to the 1985 cooling system. Moreover, even visually, that expansion tank looks too archaic for me. And I can't install the restyling expansion tank, because another interesting tank already stands in that place, but more on that later.
Finally, all the little things have arrived, and you can continue assembling the engine.


So, the M20B25 E30 cooling system is similar to the M20B25 E34. Maybe someone will say that this is a "kolkhoz", but I will say that this is an "upgrade"! :)
Cooling system water hose




Part No. 1 - water hose (11 53 1 287 651) - 1 pc.
Part No. 2 (No. 5) - clamp L42-48 (07 12 9 952 119) - 2 pcs.
Part #3 - hose holder (11 53 1 714 433) - 1 pc.

Part No. 4 - water hose (11 53 1 722 214) - 1 pc.
Part No. 5 (No. 2) - clamp L42-48 (07 12 9 952 119) - 3 pcs.
Part No. 6 - clamp L37-43 (07 12 9 952 117) - 3 pcs.
Part No. 7 - water hose (11 53 1 722 486) - 1 pc.
Part No. 8 - tube (11 53 1 719 788) - 1 pc.
Part #9 - bolt M6X16 (07 11 9 904 357) - 1 pc.
Part No. 10 - bolt with washer M6X16 (07 11 9 915 123) - 1 pc.

Part No. 11 - water hose D=45MM (11 53 1 718 982) - 1 pc.
Part No. 12 - supply hose (64 24 1 374 911) - 1 pc. Supply to the interior heater. This hose is from E30.
Part No. 13 - return hose (11 53 1 720 524) - 1 pc. Return from the interior heater. This hose is from the E34.
Part No. 14 - clamp L28-33 (07 12 9 952 113) - 3 pcs.
Part No. 15 - clamp L16-30 (64 21 8 367 179) - 2 pcs.
Part No. 16 - clamp D=24.5MM (61 13 1 379 580) - 2 pcs. Plastic clamp for interior heater hoses.
Part No. 17 - bandage 120MM (61 13 1 379 580) - 2 pcs. Plastic strap for the hose (#13) of the interior heater. It is inserted into the holes on the left spar of the restyling body. My body does not have these holes, so this part is not used in my case. Instead of them, I will use a metal bracket for the restyled body.
Detail No. 5 on the first diagram for 1985 - bracket (11 53 1 279 946) - 1 pc.

Part No. 18 - water hose (13 54 1 705 568) - 1 pc. Supply for heating the throttle. This hose is from E30.
Part No. 19 - water hose (13 54 1 289 976) - 1 pc. Throttle heating return. This hose is from E30.
Part No. 20 - clamp L15-18 (11 15 1 727 509) - 4 pcs.
Part No. 21 - wire holder (61 13 1 378 529) - 2 pcs. Plastic clamp for throttle heating hoses.
Part No. 22 - hose holder (12 51 1 309 471) - 1 pc. Plastic clamp for interior heater hoses. For restyling E30.


I installed the metal tube (#8) earlier, along with the water pump pulley.


By the way, it was because of its attachment to the pump that the pump itself had to be changed. Because before the restyling, the pump did not have this attachment.


I start installing the hoses with the interior heater hoses.
By the way, in the ETK section on heating and air conditioning, there is a separate section on these hoses.
Additional water pump / water hose




Part No. 1 - return hose (11 53 1 720 524) - 1 pc. Return from the interior heater. This hose is from the E34.
Part No. 2 - supply hose (64 21 1 380 527) - 1 pc. Supply to the interior heater. This hose is from E30.
Part #3 - clamp L28-33 (07 12 9 952 113) - 3 pcs.
Part No. 3 - clamp L16-30 (64 21 8 367 179) - 2 pcs.
All other parts for M20B25 are not used.

All hoses are original and in good condition, so I don't see the point in changing them to new Chinese ones that crack after a year... All clamps are also original, some are old, some are new.
So, I start with the interior heater hoses. On the flange of the cylinder head, we install the supply hose to the interior heater radiator.


We lay the T-shaped return hose from the interior heater radiator to the main radiator and thermostat.


We install two plastic clamps (#16) on the metal bracket and fix the hose in them.




The hose will go to the radiator along the left spar.


There it will be fixed with a metal bracket to the spar.




Next, we lay the throttle heating hoses.


We screw them to the throttle flanges.


On the flange of the cylinder block, we install the supply hose for heating the throttle.




We install two plastic clamps (#21) on the metal bracket and fix the hoses in them.


We screw the return hose from the throttle heating to the lower flange of the thermostat.


We fix the hose in a plastic clamp (#21).


So far, I have installed the plastic hose holder (#22) like this - on the oil dipstick tube.


I'm not sure how it should be, but I have no other ideas :) Maybe after installing the engine, that holder can be used to fix the fuel hose... I don't know. I'll see you later.

Let's move on to the main hoses of the cooling system.
Install the hose holder (#3). It is inserted into the hole on the bracket and fixed with a pin.


I already wrote that I laid the wire from the impulse sensor of cylinder 6 together with the wire of the crankshaft position sensor. Well, that's not right! There is a special eyelet for this wire on the slag holder. I had to extract it, then translate it correctly.


Next, we fix it in a rubber shield


And we take it to the bracket.


We install the hose and fix it in the holder.


We screw the hoses to the water pump and tube.


But to the thermostat.


All hoses of the cooling system are installed.


Next, about the engine suspension.

[The_Glory]

Really fun to watch this from you!

when do you think it will drive for first time?

It's hard to plan anything during a war...
First of all, because of the damn Muscovites, I have had problems with work for the third year already, and for the last 5 months I have been completely without a job, and accordingly, without a salary. But any project needs stable financing, so everything is delayed...
Secondly, because of the damned Muscovites, now we have electricity available for only a few hours a day, and even at night. My garage is in the basement of my house, so I can't do anything in the dark. This delays even more…
Thirdly, because of the damned Muscovites, there is now an active military mobilization, and every day there is a possibility that they will be sent to the front. In this case, it is not at all known what and how it will end... it may never end at all...
That's why I haven't set any "dead lines" for a long time - it will be as it will be...

[Mazi!]

Really fun to watch this from you!

when do you think it will drive for first time?

[The_Glory]

Collection_148. ETK_21_Clutch. Clutch

I wrote about the installation of the clutch drive a long time ago, and now it's time to write about the clutch itself.
Let's go to the ETK section
Clutch

Unit
Clutch


All the clutch parts were replaced earlier during the engine overhaul, so they are in excellent condition. So, the work is purely cosmetic - cleaning, washing, painting, galvanizing.



Part No. 1 - pressure disc D=228MM (21 21 1 223 026) - 1 pc. I am using SACHS 3082001454.

Part #2 - driven disk D=228MM (21 21 1 223 097) - 1 pc. I am using SACHS 1861661133.

Part No. 3 - release bearing lever (21 51 1 204 229) - 1 pc.
Part No. 4 - release bearing (21 51 7 521 471) - 1 pc. I am using SACHS 3151231031.
Part No. 5 - sleeve H=15MM (21 51 1 202 659) - 1 pc. I did not remove it from the manual transmission housing.

Part No. 6 - bracket (21 51 1 204 327) - 1 pc. Lever attachment.

Part No. 7 - bolt (07 11 9 919 939) - 6 pcs.
Part No. 8, No. 9 - not used.
Part #10 - set of clutch parts D=228MM (21 21 1 223 102). This is probably the original repair kit.

So the main parts of the SACHS are in excellent condition, so I just cleaned everything. The thickness of the disc is like a new one.


But it is necessary to center it somehow. I do not have the original tool, and it is not advisable to buy it for one-time use. Maybe then I'll make a homemade one. And now I used improvised means - a 12mm drill and a 16mm head;)


The 16mm head fits almost perfectly into the disc hole. By the way, on the disk it is written in German - "gearbox side". In order not to make a mistake, install the disc with the correct side.


A 12 mm drill bit fits perfectly into the hole of the head.


Also, a 12mm drill fits perfectly into the flywheel bearing hole. We insert the drill, put the head on it - and the "special tool" is ready! ;)


We put a disc on it.


And we fasten the pressure disk, tightening the bolts evenly. I used a thread lock for the bolts.


The clutch is installed.
Now we install the clutch parts in the manual transmission housing.
We fasten the new clutch cylinder with two M8 nuts.




We install the lever and the release bearing. We slightly lubricate the places of their contact.


We fix the lever with a clamp in the holes of the manual transmission housing.


Now the gearbox and clutch are completely ready for installation on the car.


The car is also ready! Finally, I wheeled her to the floor! :)


Everything is ready....almost....waiting for small details...

[The_Glory]

Collection_146. ETK_13_Preparation and adjustment of the working mixture. Throttle body

Throttle body




Almost all throttle parts are no longer available to order, so it is important not to lose them.
Part #1 - throttle body (13 54 1 707 730). I cleaned the case well, did not paint it. It comes complete with flanges for hoses, which often no longer hold in the housing. I fixed them with gasket sealant.

Part #2 - drive lever (13 54 1 714 174).
Part No. 3 - spring (13 54 1 717 027) - 1 pc.
Part No. 4 - sleeve (13 54 1 714 176) - 2 pcs.
Part No. 5 - spacer washer 19X8X0.1 (13 54 1 256 344) - 1 pc.
Part No. 6 - elastic washer (13 54 1 714 204) - 1 pc.
Part No. 7 - locking washer 8.4X13 (13 54 1 267 663) - 1 pc.
Part #8 - nut M8X1 (13 54 1 267 664) - 1 pc.
Part No. 9 - spring (13 54 1 717 028) - 1 pc.
Part No. 10 - sleeve (13 54 1 714 178) - 2 pcs.
Part No. 11 - sleeve (13 54 1 714 177) - 2 pcs.
Part No. 12 - elastic washer (13 54 1 714 204) - 1 pc.
Part No. 13 - locking washer 7.0 (07 11 9 905 858) - 1 pc.

Part No. 14 - spacer washer 13.5X8X0.5 (13 54 1 256 351) - 1 pc. I did not remove the axis, so it remained on the case.
Part No. 15 - retaining ring 8X0.8 (07 11 9 934 034) - 1 pc. I did not remove the axis, so it remained on the case.
Part No. 16 - mounting pin (13 54 1 278 976) - 1 pc. I did not remove it, so it remained on the case.
Part No. 17 - cap D=4.7MM (13 54 1 278 977) - 1 pc. No longer available to order, so I just picked up something similar in size.
Part No. 18 - screw (13 54 1 714 186) - 1 pc. I did not remove it, so it remained on the case.
Part No. 19 - ring of round cross-section (13 54 1 711 026) - 1 pc. I did not remove it, so it remained on the case.
Part #20 - BLAU cap (13 54 1 713 477) - 1 pc. No longer available to order, so I just picked up something similar in size.

Part No. 21 - sealing gasket (13 54 1 285 471) - 1 pc. I did not remove it, so it remained on the case.
Part No. 22 - cover (13 54 1 711 042) - 1 pc. I did not remove it, so it remained on the case.
Part No. 23 - bolt M4 TX20 8.8 (13 54 1 705 561) - 3 pcs. I did not remove them, so they remained on the case.

Part No. 24 - throttle position sensor (13 63 1 710 559). Took it apart, cleaned it, lubricated the contacts.
Part #25 - bolt M4 X 9.2 (13 54 1 705 562) - 2 pcs.
Part No. 26 - cap D=7.0MM (11 61 1 727 176) - 1 pc. Judging by its size and photo, this cap is used as a plug for the throttle body flange on machines without a carbon adsorber. In my case, the hose from the adsorber is put there, so the cap is not used.
Part No. 27 - gasket (13 54 1 289 576) - 1 pc. I cut it myself.
Part No. 28 - nut with washer M6 (07 14 9 156 628) - 4 pcs. Fastening the damper body to the collector.
Part No. 29 - accelerator pedal cable support SCHWARZ (13 54 1 747 519) - 1 pc. It is already installed on the car together with the cable.

In ETK, for some reason, there is another section on the throttle - a more coarse-grained one:
Throttle body




Part #1 - throttle body assembly (13 54 1 716 065).
Part #2 - throttle position sensor (13 63 1 710 559).
Part #3 - bolt M4 X 9.2 (13 54 1 705 562) - 2 pcs.
Part No. 4 - cover (13 54 1 711 042) - 1 pc. I did not remove it, so it remained on the case.
Part No. 5 - sealing gasket (13 54 1 285 471) - 1 pc. I did not remove it, so it remained on the case.
Part #6 - bolt M4 TX20 8.8 (13 54 1 705 561) - 3 pcs. I did not remove them, so they remained on the case.
Part No. 7 - cap D=7.0MM (11 61 1 727 176) - 1 pc. Judging by its size and photo, this cap is used as a plug for the throttle body flange on machines without a carbon adsorber. In my case, the hose from the adsorber is put there, so the cap is not used.
Part No. 8 - gasket (13 54 1 289 576) - 1 pc. I cut it myself.
Part #9 - nut with washer M6 (07 14 9 156 628) - 4 pcs. Fastening the damper body to the collector.
Part No. 10 - accelerator pedal cable support SCHWARZ (13 54 1 747 519) - 1 pc. It is already installed on the car together with the cable.

So, we collect all the parts of the lever, according to the scheme.




We install the sensor.


It must be adjusted on the axis so that in the extreme position of the closed flap, contacts 2 and 18 are closed, and in the extreme position of the open flap, contacts 3 and 18 are closed. I have this extreme position counterclockwise along the adjustment grooves.


After installing the throttle on the intake manifold, it will be very inconvenient to adjust. Therefore, it is better to do this before installing it.
Now you can screw the throttle to the collector, through the gasket, and connect the crankcase ventilation hose to it.






It remains only to install the hoses of the cooling system, but you need to wait until some parts for their fastening arrive.
In the meantime, I will prepare the gearbox and clutch for installation.

[The_Glory]

Collection_145. ETK_12_Engine electrical equipment. Wire harness fastening elements (part 1)

Harness fixings



There is some confusion with numbers and details, but I will try to figure it out somehow.



Part #1 - diagnostic connector plug holder (12 52 1 714 132) - 1 pc. Installed since 1986. Since I have an 86 motor wiring, the holder is also later.
Part #2 - not used. Although the picture looks like an oil dipstick tube bracket.
Part No. 3 - plate (12 14 1 269 699) - 1 pc. Not available to order. I don't know what it is, I probably don't have one. If anyone knows, I would be grateful for the information.
Part No. 4 - plate (12 42 1 289 510) - 1 pc. Not available to order. I don't know what it is, I probably don't have one. If anyone knows, I would be grateful for the information.
Item No. 5 is not used. But there is a mistake here.
Part No. 6 - bracket (12 52 1 711 228) - 1 pc. In fact, judging by the photo, this is part #5. Bracket for motor wiring. It is installed under the hood, on the shield of the interior heater fan niche.
Part No. 7 - bracket (12 52 1 285 040) - 1 pc. I don't know what it is, I probably don't have one. It looks like a connector holder for ABS or Airbag sensors.
Part #8 - bracket (12 52 1 714 333) - 1 pc. "Ground" terminal on the right support of the body.
Part #9 - not used.
Part No. 10 - bracket (12 52 1 719 510) - 1 pc. Bracket for motor wiring. It is installed under the intake manifold.
Part No. 11 - bracket (12 52 1 288 127) - 1 pc. Not available to order. But there is a mistake.
Part No. 12 - bracket (12 52 1 719 521) - 1 pc. In fact, judging by the photo, this is part #11. I don't know what it is, I probably don't have one. If anyone knows, I will be grateful for the information.
Part No. 13 - ground wire 235MM (12 51 1 714 039) - 1 pc. In fact, judging by the photo, this is part #14. I already wrote about it earlier - the wire to the "mass" of the engine.
Part #14 - not used. But there is a mistake.

In this part, I will write only about parts #1, #5 and #10, because they are installed on the engine. I will write about other details after installing the engine on the car.

So, the bracket (#10) is screwed with two M6 nuts to the studs on the intake manifold.


Together with it, the bracket for the oil dipstick tube, which I already wrote about earlier, is fixed to the front stud.


This bracket serves to fix the engine wiring and cooling system hoses. About this in the corresponding section.


The bracket (#1) is screwed with an M8 nut to the upper stud on the intake manifold.


The plug of the crankshaft position sensor is fixed in it.


The plug of the pulse sensor of the position of the camshaft is also fixed there.




I routed the two wires together behind the pulleys, but I guess that's not right. After installing the cooling system hoses I will check it. If I was wrong, I will write about it later.

Next, I will install the throttle.


P.S.
I installed an alarm with a magnetic lock a long time ago, but I did not install the lock itself, because for some reason the paint did not stick to its coating. Finally, I solved this problem - sandblasting, priming and painting. Now the paint is holding up well.


And finally I installed it. The cover of the lock with the diode is inserted through the rubber gasket from the outside, and the lock from the middle. Then it is fixed with an elastic clamp.


We connect to the door wiring, fix the plug with a clamp.


Now everything is installed.


Two locks! ;)

[The_Glory]

Collection_144. ETK_12_Engine electrical equipment. High voltage wire. Spark plugs

The engine is almost assembled, it remains to wait for a few new parts to it. Therefore, let's move on to the ETK section

Engine electrical equipment

Let's start with the subdivision
High voltage wire




Part No. 1 - High voltage wire cylinder No. 1 (12 12 1 710 631) - 1pc.
Part #1 - High voltage wire cylinder #2 (12 12 1 710 632) - 1pc.
Part No. 1 - High voltage wire cylinder No. 3 (12 12 1 710 633) - 1 pc.
Part No. 1 - High voltage wire cylinder No. 4 (12 12 1 710 634) - 1pc.
Part No. 1 - High voltage wire cylinder No. 5 (12 12 1 710 635) - 1pc.
Part #2 - High voltage wire cylinder #6 (12 12 1 717 375) - 1pc. With a pulse sensor of the position of the camshaft.
Part No. 3 - Central high voltage wire T1KL4 (12 12 1 720 601) - 1pc. Wire to the ignition coil with a protective rubber cover.

I have a set of BOSCH wires. They are in good condition and their resistance is as rated. Somewhere on the Internet I found information that the high-voltage wires for the M20B25 should have a resistance of about 6 kΩ, and the central wire should have a resistance of 2 kΩ. The results of my measurements are similar - the top row of numbers:


By the way, there is an interesting original option - "Jute of high voltage wires with protection against rodents"! :)

Harness high voltage with rodent protection


This is a set of high-voltage wires with protective plastic rings on them, and an additional plastic cover. Apparently they are made of plastic, which rodents do not like the taste of! :)


Part No. 1 - High voltage wiring harness with rodent protection (12 12 1 735 217). No longer available to order.
Manufacturer of wires

In addition to protection against rodents, I discovered another interesting thing - the resistance of these wires is much lower - only 1kΩ (bottom row of numbers). I heard something about low resistance wires - could that be them? I don't think it's a coincidence, because the four wires have the same indicators. The last two wires are obviously broken. And in general, their condition is bad. I took them, hoping to rearrange the plastic rings on my wires - to replenish my collection of original options ;) But for this, the wires will have to be cut and the contacts re-crimped. Didn't do it. Maybe later I will try to cut the rings and rearrange them in this way.


The plastic cover can be ordered only complete with wires. It has a number on it (12 12 1 735 181), but for some reason such a number is not in ETK. Therefore, it will not be possible to order it separately.


This cover fits well with the standard cover.


Spark plugs




Part #1 - spark plug BOSCH W7 DCR (12 12 9 061 871) - 6 pcs.
Part #2 - a kit for 4-cylinder engines. Not available to order.
Part #3 - a kit for 6-cylinder engines. Not available to order.

I always use NGK ZGR5A spark plugs.


High voltage wiring harness




Part No. 1 - high voltage wiring harness (12 12 1 710 664). The set includes all parts, except for parts No. 12...No. 15.
Part #2 - cable (12 12 1 719 889). Plastic pencil case for wiring.
Part #3 - high voltage wire (12 12 1 705 675). Probably sold by the meter.
Part #4 - marking ring cylinder #1 (12 12 1 706 186) - 1 pc.
Part #4 - marking ring cylinder #2 (12 12 1 706 187) - 1 pc.
Part #4 - marking ring cylinder #3 (12 12 1 706 188) - 1 pc.
Part #4 - marking ring cylinder #4 (12 12 1 706 189) - 1 pc.
Part #4 - marking ring cylinder #5 (12 12 1 706 190) - 1 pc.
Part #4 - marking ring cylinder #6 (12 12 1 706 191) - 1 pc. Plastic tags on the wire with the corresponding number. My wires are marked, so I have not ordered these tags yet.

Maybe I'll order one later, for beauty, although they won't be visible under the lids anyway :)
Part No. 5 - cylindrical connector (12 12 1 705 656) - 14 pcs.
Part No. 6 - KBB 1000-OHM interference-suppressing plug (12 12 1 289 829) - 7 pcs.
Part No. 7 - 1000-OHM interference-suppressing plug (12 12 1 289 825) - 1 pc.
Part #8 - 5000-OHM spark plug wire tip (12 12 1 289 821) - 6 pcs.
Part No. 9 - rubber sleeve (12 12 1 710 584) - 1 pc. Instead, I will install an additional plastic "rodent protection" cover. She looks more beautiful.
Part No. 10 - protective cap (12 12 1 284 464) - 1 pc. Rubber cover for the ignition coil.
Part #11 - not used.
Part No. 12 - ignition distributor cover (12 11 1 715 905). Comes complete with plastic cover, bolts and washers for mounting.

Part No. 13 - ignition distributor rotor (12 11 1 715 906). Comes complete with bolts and washers for mounting.

Part No. 14 - cover (12 11 1 287 718). Protective plastic cover of the camshaft gear.
Part No. 15 - protective cap (12 11 1 710 553) - 1 pc. Plastic cover.
Part #16 - spark plug BOSCH W8DC (12 12 1 276 283) - 6 pcs. As I said, I always use NGK ZGR5A spark plugs.

So, we put on a plastic cover, insert bolts with washers into the cover and the rotor.


Insert the plastic gear cover and fasten the rotor with three screws.


We fasten the cover with three bolts.


Carefully and tightly place the wires in a plastic case, according to their number and length. Align their ends and close the pencil case with a lid. The pencil case is screwed with two nuts to the studs, together with the valve cover.
Because of the damned Muscovites, the lights were turned off again, so we had to install the wires already in the dark...
The cover (#15) snaps onto the lower plastic cover. Then a plastic "rodent protection" cover is put on the pencil case (#2) and the lid (#15).




The appearance with it is much better, although it somehow did not become very tight. It will be necessary to somehow press it a little.




High voltage wires are installed.


It remains to fasten several brackets for wiring, and lay the wire of the impulse sensor of the sixth cylinder.