Project Weißer Regen: 91 318iS Restomod

[rzerob]

Good god Jordan. I almost had a heart attack reading your post. I can only imagine how I would have felt had I been behind the wheel.

[RobE30]

Sounds like a happy ending! That pump is impressive

[Digitalwave]

Glad you didn't smack the curb! I saw you talking about offering this rebuild as a service, and the ballpark price you posted seemed well deserved when you look at the exploded view of the parts.

What was the condition of all the rubber seals and o-rings? Did you re-use them all?

[Jordan]

Glad you didn't smack the curb! I saw you talking about offering this rebuild as a service, and the ballpark price you posted seemed well deserved when you look at the exploded view of the parts.

What was the condition of all the rubber seals and o-rings? Did you re-use them all?

I can't speak for every pump out there but in the case of my pump, and the spare pump I tore down for extra inner parts selection all of the orings were in splendid shape. No flattening, or hardening. All seals still soft and supple as new with no signs of aging. Whatever material Bosch specified for these is very high quality and has been altogether unbothered by exposure to brake fluid over the years.

Given the soft and plump nature of most of them I see no reason why they cannot be reused once thoroughly cleaned and lubricated upon reassembly with fresh clean brake fluid.

[Jordan]

Finished assembling the pump last night, got it installed in the car this evening, and got it thoroughly bled with a power bleeder. Bleeding process was a bit more intensive than normal given the amount of air pockets in the pump but it went straight forward. Bled each caliper in order with just the power bleeder but still had a mushy pedal. Then had my wife pump the pedal 5 times per bleed, 3 times per caliper and the pedal was solid as a rock.

I've bled the brakes on a lot of E30's and I can say I have NEVER seen fluid move out the caliper bleeder nipple with the speed and volume this car has now...

[redneckvtek]

Did you find a source for the anti-tamper caps, or can you get them off and on now without damaging them?

[Jordan]

Did you find a source for the anti-tamper caps, or can you get them off and on now without damaging them?

I had a special tool machined to remove them. Essentially a Giant-ass-torx to 24mm socket adapter.

[redneckvtek]

ABS pump with the missing anti-tamper top cover cap because it looks like the platers lost it..... I'll have to destroy another ABS pump to remove one intact and then send just it out for playing... le'sigh.

Sorry, I was referring to the plated dust cap on the top referred to in post 650 (page 44)

[Jordan]

Sorry, brain fart there... I devised a method to remove them without too much damage so I can reuse them. It would be easier to find replacements, but I haven't had time to look into that as of yet.

[Pootis]

Hey Jordan when you put your windshield back in did you source the oem tape that goes under gasket?

[Sh3rpak!ng]

So is it unreasonable to think that there may be many E30s out there with underperforming brakes due to such build up in the ABS unit? But otherwise fresh brake system? (calipers, lines, MC, reservoir etc.)

That is really disturbing to see the gunk inside the unit.

[Melon]

Super cool to see this taken apart. Thanks, as always, for documenting the rebuild.

[Jordan]

Hey Jordan when you put your windshield back in did you source the oem tape that goes under gasket?

I did not reinstall any of that. Its sheet butyl tape with a thin plastic layer over it. I believe it is primarily for corrosion resistance, but who knows.

So is it unreasonable to think that there may be many E30s out there with underperforming brakes due to such build up in the ABS unit? But otherwise fresh brake system? (calipers, lines, MC, reservoir etc.)

That is really disturbing to see the gunk inside the unit.

I think its entirely and very likely possible to be the case. The bias limiting valve on the frame rail is going to have some build up on it as well, and all of the caliper bodies always have some inside when you rebuild them. Fact of the matter is that brake fluid is hygroscopic, it absorbs water, and water attacks metals over time. Those corrosively lifted metal particles become suspended in the fluid and eventually find a resting place.

I'll have time to go drive the car this weekend and can report back on overall brake feel and response with the "new" pump.

Super cool to see this taken apart. Thanks, as always, for documenting the rebuild.

It is REALLY cool to see it blow all apart, it is far more complex inside than I gave it credit for.

[Vincenze]

With the hardware off the plate that's left me to finish working on the chassis harness I started on the weekend before. The ABS wheel speed sensor repair kit harnesses came in, and I also managed to find a solution for the dry rotted brake pad wear sensor harnesses which unfortunately are not available new.

Pro tip, SRS harness wiring is the same size jacket as the brake pad wear sensor, but isn't made out of shit that dry rots. Damn wire colors are even the same. Since I'm removing SRS from this car I used that wiring as a donor to repair the brake pad wear sensor harness, sliding the rubber boots and hangers off the original junk and over the new.

I wonder if this line can be used?
https://www.ecstuning.com/b-genuine-...e/61121367674/

It has an additional ground connector, though.



Also, is there a cheaper substitute for the grommet 61611356460?

[Jordan]

That is the brake pad wear sensor repair harness for early cars, yes they have a redundant and altogether unnecessary ground that was eliminated on later cars. If it came with the tapered boots that interface with the struts I feel there would be a case to use it, but as it doesn't... I passed it over.

There most likely is a more cost effective solution for the grommet, but then it wouldn't be correct. $25ea is a bit insane for what it is, but we don't use the C word around here sir.