Spasso's Euro 635 #5546139

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tschultz
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Post by tschultz »

Spasso wrote:Got the master cylinder replaced today.
Pretty much straight forward but was surprised at having FIVE brake lines connected to it.
I noticed two separate brake lines to each front caliper and three bleeders on each.
Quite a set-up.

Tomorrow I'll try out my pressure bleeder for the first time.

Next on the agenda, R & R the idler arm, RH side. It moves up and down about 1/4".
How was this job? It's on my to-do list!
http://www.Drive4Corners.com
Image
'79 635CSi Revival
'80 635CSi
'83 633CSi Callaway Turbo continued as 1988 535is Turbo
SOLD: '81 635CSi/A
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Spasso
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Post by Spasso »

I spent about 4 hours today for the bleeding process, more accurately, the flushing process. I took my time and only ran 10 to 12 psi.
I can't believe I've waited this long to get a pressure bleeder.

- The 4 hours included set up time and cleanup of the equipment after with denatured alcohol. I had to pull the front wheels off too.

- The "Euro" cap that came with the pressure bleeder fit perfectly. I used a Motive Products XLT Bleeder with their catch bottle #1810. The catch bottle comes with hose and a cable attached to the neck so it can be hung from the underside of the car if required. Well thought out.

- All of the bleeders came loose easily except for an intermediate fitting on one front caliper. Some were plugged and had to be removed completely for cleaning. This required depressurizing the system but at no time risked intake of air.

- I ran a total of 2 full quarts of fluid through the entire system including the clutch master and slave. The clutch master is fed from a spud on the side of the main reservoir so it was simple to do.

- I started at the back and finished at the front. I probably ran 1/3 of a pint (or more) through each individual line to enure that not only was all the dirt flushed out (and there was dirt) but to make sure all of the moisture was out.

- The slave for the clutch looks like it was recently replaced but when I flushed the clutch master and slave I got some really dark stuff out of it. I probably ran 3/4 pint through that until it was coming out relatively clean.

- I got everything put back together and took the car for a drive and everything felt pretty good except I kept hearing some rubbing under hard braking. Come to find out that the raised rubber ridge around the inside of the tire, next to the rim, rubs on the side of the strut housing.

- Previously I was dealing with the tires rubbing on the fender lip so I thought by going to these style 4's was the ticket. Now the problem is inboard. I'm not real hot on wheel spacers for the minimal amount of clearance that I need so I may move these 225/50-16 tires to the back and replace the rears with 215/50-16's to install on the front. The 245/50-16's on the rear are getting down there anyway.
Last edited by Spasso on Mon Jul 21, 2014 5:51 am, edited 1 time in total.
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Spasso
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Post by Spasso »

A couple of things to make access to the master cylinder easier is to unbolt the 3 relays mounted above the master cylinder and drape them back by the firewall. No need to unplug them.

With that done there was only one bolt holding the header tank so I undid that and swung the tank forward and inboard as far as the hoses would allow. I did not disconnect any of the hoses either.

This makes access much easier for fat hands and thick arms. :wink:
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Spasso
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Post by Spasso »

tschultz wrote:
How was this job? It's on my to-do list!
I don't know if you've bench bled and master cylinder before but with a standard dual line master it's pretty easy, You Tube videos galore.
It only takes two lines from the outlets, looped over to back feed the reservoir. Pump the cylinder until you see no more bubbles.

With this master there are 5 outlets and the reservoir is closed over one of two feed ports on top.

I found this video showing how to bench bleed using a large plastic syringe with a rubber stopper on the tip. ( I already had the syringe and bought the rubber part at the hardware store.).
http://www.youtube.com/watch?v=USdtwqju4GY

Here is an abreviated version.
http://www.youtube.com/watch?v=IHLi4tyFcJo

In order to follow the video I took the reservoir off the master so I could access both feed ports.

I used a separate cup full of fluid for a source.

With the master in my bench vice (leveled), I placed a large drain pan underneath to catch the spent fluid. There was really no way to recycle it as shown in the videos.

I injected fluid into the inlet ports first to fill the master cylinder and force air out the outlets.

Then I back-flushed fluid through the outlet ports one at a time, plugging them with rubber stoppers as I went, making sure no air was coming up out of the inlet ports.

Keep the rubber plugs in the outlets after back-flushing and then slightly larger stoppers in the inlet ports (on top) to keep the fluid in the cylinder during installation.

- Once the master is bolted to the diaphragm I would pull one of the small stoppers out of the bottom and install and tighten the line until all 5 were done. Not too much drippage because the upper stoppers were still installed.

- Then I took the two larger stoppers out of the top and installed the reservoir. From there it's time to bleed the car.
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Spasso
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Post by Spasso »

Spasso wrote:
- Previously I was dealing with the tires rubbing on the fender lip so I thought by going to these style 4's was the ticket. Now the problem is inboard. I'm not real hot on wheel spacers for the minimal amount of clearance that I need so I may move these 225/50-16 tires to the back and replace the rears with 215/50-16's to install on the front. The 245/50-16's on the rear are getting down there anyway.
- Well, further investigation of a smaller tire isn't looking so good.
It appears that the 215/50-16 is a little harder to get. Even the narrower tire is still going to have the "rim protector" shelf at the lip so it looks like I'll still have a riding condition.

- It looks like I need at least 1/4" minimum outboard shift to make it right.
- I can't go back to the Rondell 58's because they hit the fender lips when turning so if I stay with these I might have to opt for the spacers.


Thanks.
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Spasso
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Post by Spasso »

Looks like I'll be going with some spacers.
They are hub centric with center lips so shouldn't cause any balance or shimmy issues.
- No more expensive than changing tire sizes.
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Spasso
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Post by Spasso »

Finally got the wheel spacers installed today and took it for a drive.
For the first time since buying this car there is no rubbing anywhere.

I did some figure eights, lock-to-lock with not a peep.
The wheels are 8 x 16 and have a backspacing of 23mm so I added some ECS spacers with hubcentric lips, 12.5mm (1/2"), and new longer bolts.

Tires:
225/50-16 on the front.
245/60-16 on the rear.

Now that there is no rubbing I was able to do some panic stops to test the new master cylinder. All clear, nice and smooth in a straight line.

Cooling system is working as it should.

So for the first time since purchase this car is actually road worthy. (more or less).

I ran through the back roads around here and it drives quite nice. Straight tracking with really no appreciable slop in the steering, even though there is some up and down play in the idler arm.

More work to follow. The list never ends.
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ZROSSA
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Post by ZROSSA »

They look just like mine. I just sold them to a friend who has a red 79 635.

Your going to have a twin down under!

Douglas
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tschultz
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Post by tschultz »

Looks sharp!
http://www.Drive4Corners.com
Image
'79 635CSi Revival
'80 635CSi
'83 633CSi Callaway Turbo continued as 1988 535is Turbo
SOLD: '81 635CSi/A
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Spasso
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Post by Spasso »

ZROSSA wrote:They look just like mine. I just sold them to a friend who has a red 79 635.

Your going to have a twin down under!

Douglas
Cool!
Now he'll know what to look for when he mounts up.
Post up some pictures.
Last edited by Spasso on Tue Jul 29, 2014 1:11 am, edited 1 time in total.
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Spasso
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Post by Spasso »

tschultz wrote:Looks sharp!
Thanks.
This style of wheel seems to fit the character of the car.
Could use a little more lip but these will do nicely.

It drives better with these over the Rondell 58's.
sunnyxuan106

Are you in seattle?

Post by sunnyxuan106 »

Are you in Seattle? We should meet up sometimes, I have a 1983 635csi.
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Spasso
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Post by Spasso »

Beautiful car you have there.

I'm about 65 miles north of Seattle.
Once I get this one squared away a little better I plan on taking it down to ERTC (Exotics@Redmond Town Center) on a Saturday morning (if I can get up that early).
http://www.exoticsat.com/

It's getting close but have a list of little detail items that need attention.
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hornhospital
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Post by hornhospital »

I resized that photo for you.... Nice car!
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Ken Kanne
'84 633CSi "Sylvia"; '85 635CSi "Katja";'85 325e "Hazel Ann"; '95 M3 "Ashlyn"
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Spasso
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Post by Spasso »

That's as nice as it gets.
Gorgeous.
I'll have to make sure I don't park right next to it when we meet. :wink:
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Spasso
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Post by Spasso »

I spent the day doing a full buff, wax and detail.
I think my back is telling me I'm getting too old for this.

Those style 4's really look nice on this car. Glad I made the choice.
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Spasso
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Post by Spasso »

More
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Spasso
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Post by Spasso »

Well, I didn't think this would happen when I bought this car, thinking this is definitely a keeper (and it is), but today I said goodbye to Gretchen.

- I was contacted a month ago by an acquaintance from another car club. He knew I had 635's and was asking if I knew of any E12 based cars for sale.

- I told him I had one I might consider selling once I completed the work I was doing on it.

- He came by last Saturday and performed a meticulous inspection on the car and we came to mutual price, with compromise of course.

- Today we completed the transaction and she will be going to the new home of an automotive enthusiast that has an eye for detail. I think the car will be treated well and brought to the higher level of restoration I had planned.

- Still kind of sad though.........:(

- Loren will be making an introduction here on the site in the next few days. 8)
Last edited by Spasso on Fri Aug 22, 2014 12:45 am, edited 1 time in total.
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tschultz
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Post by tschultz »

I never expected this!!
http://www.Drive4Corners.com
Image
'79 635CSi Revival
'80 635CSi
'83 633CSi Callaway Turbo continued as 1988 535is Turbo
SOLD: '81 635CSi/A
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Spasso
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Location: The Jet City, USA

Post by Spasso »

Me neither. It just sort of fell in my lap and the terms were met.

Part of it is because I have too many automotive projects plus the house and shop to take care of.

I just talked to the buyer and he had a great drive home. He loves the car.

I still have "Scheiße-Haufen" (S**tpile) so not all is lost. I'll still be around.
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Spasso
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Post by Spasso »

I figured I would share the links and info I gathered during my research for this car.


BMW On-line Vendor List


Alleurasianautoparts Ã
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Spasso
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Post by Spasso »

In case you don't know your BMW model designation:

114 1602 - 2002tii
118 1500, 1600-4, 1800, 1800tii
120 2000C/CS/CA
121 2000, 2000ti, 2000tilux
E3 2500 - 3.3Li
E6 1600, 1800, 2000 touring
E9 2500CS - 3.0 CSi
E12 5 Series cars from 1974 to 1981
E21 3 Series cars from 1976 to 1983
E23 7 Series cars from 1977 to 1986
E24(E12) 6 Series cars from 1976 to 1981
E24(E28) 6 Series cars from 1981 to 1989
E26 M1
E28 5 Series cars from 1981 to 1987
E30 3 Series cars from 1984 to 1991
E31 8 Series cars from 1989 to 1997
E32 7 Series cars from 1986 to 1994
E34 5 Series cars from 1988 to 1995
E36 3 Series cars from 1992 to 1999
E36/5 318ti
E36/7 Z3 Roadster
E38 7 Series cars from 1994 to 2001
E39 5 Series cars from 1995 to 2003
E46 3 Series cars from 1999 to 2004
E52 Z8 Roadster
E53 X5 SAV
E65 7 Series cars from 2002 (short wheelbase)
E66 7 Series cars from 2002 (long wheelbase)
E85 Z4 Roadster
E60 5 Series cars from 2003
E90 3 Series cars from 2005
Last edited by Spasso on Fri Apr 10, 2015 3:12 am, edited 1 time in total.
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Spasso
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Post by Spasso »

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Spasso
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Post by Spasso »

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Spasso
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Post by Spasso »

Additional 635 links and .pdf downloads:

E24 DIY Links
http://forums.bimmerforums.com/forum/sh ... ?t=1360890

E24 Pdf. Downloads
http://forums.bimmerforums.com/forum/sh ... ?t=1394945
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