I am new to the forum and I am posting this as it might help those trying to get the e90 brake booster to fit with the OBD1 intake manifold. I searched alot of threads and posts on the topic but could not find any definitive info on how get it to work.
The problem i ran into is that the e90 booster with e90 master cylinder and brake fluid reservoir do not clear the throttle body and more specifically, they do not clear the throttle position sensor. I tried about 6 or 7 different reservoirs from different BMW models but none worked. So the only solution i found is to remote mount the brake fluid reservoir and connect it to the MC with hoses. I was able to find a stock 92 BMW 7 series (E32) remote mount brake fluid reservoir with two fluid outlets at a local pic a part and it worked perfectly. I also got the plastic MC fittings from the same car . As far as connection to the brake pedal, all i had to do is take the stock U-shaped e30 bracket from the booster (the one with the threaded hole at the back of it) and weld it to the U-shaped e90 booster bracket and it fit perfectly, no cutting or rethreading needed.
I also used a separate reservoir and bracket for the clutch fluid which i got from believe it or not, a saturn, see pics, and that too worked perfectly. I still had to shave down a couple of fins on the intake manifold that were almost touching the brake booster.
I hope this helps anyone trying to use an e90 booster and MC combo in their M50/S50 swap with the OBD1 manifold.
The problem i ran into is that the e90 booster with e90 master cylinder and brake fluid reservoir do not clear the throttle body and more specifically, they do not clear the throttle position sensor. I tried about 6 or 7 different reservoirs from different BMW models but none worked. So the only solution i found is to remote mount the brake fluid reservoir and connect it to the MC with hoses. I was able to find a stock 92 BMW 7 series (E32) remote mount brake fluid reservoir with two fluid outlets at a local pic a part and it worked perfectly. I also got the plastic MC fittings from the same car . As far as connection to the brake pedal, all i had to do is take the stock U-shaped e30 bracket from the booster (the one with the threaded hole at the back of it) and weld it to the U-shaped e90 booster bracket and it fit perfectly, no cutting or rethreading needed.
I also used a separate reservoir and bracket for the clutch fluid which i got from believe it or not, a saturn, see pics, and that too worked perfectly. I still had to shave down a couple of fins on the intake manifold that were almost touching the brake booster.
I hope this helps anyone trying to use an e90 booster and MC combo in their M50/S50 swap with the OBD1 manifold.
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