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.

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Test Drive Update

Alright. Been driving it for about a month with everything done, including alignment and all the work done performs well.

Steering Rack: The new (to me) steering rack is great! No more bus-like loose feel. It’s tight and more responsive. I feel the road more with it. Much nicer on the freeway. Don’t do any tracking or hard driving so turn to turn ratio is not a major factor for me even though the new set up is shorter.

Front Suspension: It’s definitely tighter and I can tell from past to now. Simple things like going over the speed bumps is noticeable and nicer. No bouncy reaction. From height standpoint, I will get the actual measurement, but the front valance is a tad lower than an 2025 BRZ/GR86 (did a comparison but forgot the measurements). There’s a little front rake (front lower than back). I like this stance. I will get the rear suspension refreshed at some point to get it fully complete.

Front Brakes: Maybe little better. Previous set up fine. It has new rotors, brake pads, fluid, pistons, hoses, so just glad that’s been refresh.

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For next thing to tackle, I’m thinking about the AC system after I get to enjoy the E30 for few months.

Figure the AC project might take little more time to research, source and execute.

So, if anyone has any experience or wisdom on this topic, please chime in.

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Current AC System Set-Up

It’s 100% stock and original. So, as of today, 35 years old. Never messed with it. It is R-12. The AC shop added some R-12 about 5 years ago and changed out the resistor at the condensor fan.

Overall, it runs good now but not always comfortable. The fan/blower speed works. It runs around 60-65 degrees during summer time. Colder (50-60f degrees) during winter/fall/spring. I just want a cooler system during Texas summer months to make it more comfortable. Sitting in traffic in 100 degree is no fun when the air starts warming up.

To start things off,

1. I wanted to see what the state was on the AC system. So, I took it to a reputable AC shop here this week and they discovered my compressor is leaking.

2. Got some quotes for windshield and window tinting. Front wouldn’t be tinted but rather ceramic coat for heat shield. Figure this would help reject heat as much as possible to keep the cabin cooler.

Things I’m considering….

- Convert to R-134. Just want it easier to maintain for future
- Complete new AC system including hoses, minus the evaporator
- Window Tints/Ceramic Coat Film

What I’m learning is that you can’t buy a new OE or OEM compressor anymore for M42. Hearing and reading reman are not reliable and some kits from AC Solution but not a full kit. So, I have to figure out how to source all these new parts from multiple sources. I’m okay with AC system not being OE or OEM at this point but do want a OE/OEM look. I may look at getting custom hoses made.

Example of current temp:

[Digitalwave]

I'm in love with this car. Excellent work! Keep it up.