1991 318is M42 Refresh Journey

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FRONT STRUTS (REFRESHED)

Got all the parts in and tackled it this weekend and got it complete.

I did have to borrow a coil spring compressor from nearby auto store with the shorter Koni''s shock to get everything installed. When disassembling, since it had OEM Bilstein shock, there was no tension.

I also got a tip from a fellow forum member about installing and ordered a new E30 Top Hat Washers (Part #31306763966) vs. using E30 Top Hat Washers since I was using a E90 Top Hat.



Used Koni provided plastic bump stop, top washer (OE version does not fit), locking washer and nut.

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For me, I assembled the shock, coil springs, etc. on a bench and then installed the new dust shield, bearing, brakes, etc on the vehicle. I ended up torquing the wheel bearings while the car was on stands. Didn't have to lower it with tires on it. Used dremel to cut the nut to locked it. Below is the high level sequence.

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FRONT BRAKE CALIPERS

I got the original front calipers rebuilt by PMB Performance. When I did the math of reordering new parts (sliders, rubbers, etc), media blast and zinc plating, it just made sense to send it off and get it rebuilt.

Below shows how it looked in original state. After 35 years, nothing was going to come off from just washing and brushing it. Media blasting was the only way.

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Here's how it looks after being rebuilt by PMB Performance. It comes fully assembled ready to go.

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Here's the rotors and pads. I've had the new EBC pads and Zimmermann rotors that I've been waiting to install at some point. Was waiting for the previous to wear down but never got to that point until now. I also ordered new brake lines. I ended up going with OEM rubber lines. Been thinking about stainless steel versions but since I'm keeping everything pretty stock with engine, etc. figured OEM is perfectly fine. Did a full brake fluid flush since the reservoir was drained while doing this project as well.

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Took it to the alignment shop and got it all aligned. Here's how it looks now from underneath the car...

Here's the driver side:




Here's the passenger side:



Got the plastic protective engine cover back on. I also cleaned up the plastic cover as it was baked on with cosmoline.