Big Brake conversion E28/E24

This conversion set up is to go on the 535i E28 and 635csi  E24 cars (Not for E30 or E36 use)

Front Brakes:

E32 (all US models, 735, 740, 750)
The calipers are single piston. To be used with 302mm diameter x 28mm thick rotors.
Caliper part #: 34 11 1 160 363/364 (199.50 Eur)
Rotor Part #: 34 11 1 159 896 (superceded by 34 11 6 756 090) (72.30 Eur)
Carrier Part #: 34 11 1 160 365 (91.80 Eur)
Note: E36 US M3 pads can fit this application.

E28 M5/ E24 M6 (US and Euro)
The calipers are 4 piston. To be used with 300mm diameter x 30mm thick rotors. E32 302mm diameter x 28mm thick rotors can be substituted.
Caliper Part #: 34 11 2 225 002/003 (432.60 Eur)
Rotor Part #: 34 11 2 225 007 (102.60 Eur)
Substitute Rotor Part #: 34 11 1 159 896 (superceded by 34 11 6 756 090) (72.30 Eur)
No carrier.

E34 (all US models, 525i/535i/530i)
The calipers are single piston. To be used with 302mm diameter x 22mm ventilated thick rotor.
Caliper Part #: 34 11 1 160 367/368 (194.00 Eur)
Rotor Part #: 34 11 1 160 936 (75.50 Eur)
Carrier Part #: 34 11 1 160 366 (91.80 Eur)

E34 (540i, US model)
The calipers are single piston, floating. To be used with 302mm diameter x 28mm thick rotors.
Caliper part #: 34 11 1 160 363/364 (199.50 Eur)
Rotor Part #: 34 11 1 159 896 (superceded by 34 11 6 756 090) (72.30 Eur)
Carrier Part #: 34 11 1 160 365 (91.80 Eur)

E34 M5 3.6 (US model), E34 540i Sport (US model)
The calipers are single piston. To be used with 315mm diameter x 28mm thick rotors.
Caliper Part #: 34 11 2 226 407/408 (also 34 11 2 226 873/874) ( 281.00 Eur)
Rotors Part #: 34 11 2 226 385 (100.50 Eur)
Carrier Part #: 34 11 2 226 875 (136.50 Eur)

E34 M5 Euro Nurburgring brakes
The calipers are 4 piston calipers, to be used with 345mm diameter x 32mm thick directionally ventilated rotors.
Caliper Part #: 34 11 2 227 115/116 (555 Eur)
Rotor Part #: 34 11 2 227 735/736 (198 Eur)
No carrier.

E31 (US model, up to 8/93)
The calipers are single piston. To be used with 324mm x 30mm thick rotors
Caliper Part #: 34 11 1 160 325/326 (215.00 Eur)
Rotor Part #: 34 11 1 159 895 (77.50 Eur)
Carrier Part #: 34 11 1 160 327 (94.50 Eur)

E31 (US model, after 8/93)
The calipers are four piston, known as “Brembo” brakes. To be used with 324mm x 30mm thick rotors.
Caliper Part #: 34 11 1 161 177/178 (289.00 Eur)
Rotors Part #: 34 11 1 161 086 (superceded by 34 11 6 756 087) (100.50 Eur)
850CSi Rotor Part #: 34 11 6 757 746 (75.50 Eur) (same used on E32 750i Euro, and E38 and E39 V8 engine cars).
No carrier.


Rear Brakes:

E34 non-vented (US model 535i/530i/525i)
The calipers are single piston. To be used with 300mm x 10mm thick solid rotors
Caliper Part #: 34 21 1 157 557/558 (superceded by 34 21 1 160 381/382) (135.50 Eur)
Rotors Part #: 34 21 1 162 305 (superceded by 34 21 1 160 305) (49.00 Eur)
Carrier Part #: 34 21 1 160 383 (83.10 Eur)

E34 vented (US model 540i/M5/540i Sport)
The calipers are single piston. To be used with 300mm diameter x 20mm thick vented rotors
Caliper Part #: 34 21 1 159 657/658 (superceded by 34 21 1 160 399/400) (155.00 Eur)
Rotor Part #: 34 21 1 165 265 (70.80 Eur)
Carrier Part #: 34 21 1 160 384 (83.10 Eur)

E32 non-vented (US model 735)
The calipers are single piston. To be used with 300mm diameter x 12mm thick solid rotors. E34 solid rotors are required. Carrier information as to which is acceptable is unavailable at this time.
Caliper Part #: 34 21 1 160 353/354 (152.00 Eur)
Rotor Part #: 34 21 1 165 257 (60.50 Eur)
Carrier Part #: 34 21 1 160 355 (83.10 Eur)

E32 vented (US model 740i/750iL)
The calipers are single piston. To be used with 300mm x 20mm thick vented rotors (E34 vented rotors must be used!)
Caliper Part #: 34 21 1 160 399/400 (155.00 Eur)
Rotor Part #: 34 21 1 165 265 (540i) (70.80 Eur)
Rotors that came on E32 Part #: 34 21 1 162 967 (will not fit E28/E24 application. Reference use only.) (69.80 Eur)
Carrier Part #: 34 21 1 160 384 (83.10 Eur)

E34 Nurburgring (M5 Euro)
To be sued with 328mm diameter x 20mm thick vented rotors.
Caliper Part #: 34 11 2 227 873/874 (191.00 Eur)
Rotor Part #: 34 11 2 227 844 (93.40 Eur)
Carrier Part #: 34 11 2 227 875 (127.00 Eur)

Here are an example list of stages of braking upgrades and the minimum wheel size you can safely fit. The amount of benefit you receive from the upgrade is mainly dependant on the pads and rotors you use.

Stage 1: E32/540i fronts
Minimum wheel size: 15” wheels
Stage 2: E28 M5/ E24 M6 fronts
Minimum wheel size: TRX, only *some* 15” wheels, 16” wheels
Stage 3: E32/540i fronts, E34 solid rears
Minimum wheel size: 15” wheels front and rear
Stage 4: E28 M5/ E24 M6 fronts, E34 solid rears
Minimum wheel size: TRX, only *some* 15”, 16” wheels front; 15” wheels rear
Stage 5: E32/540i fronts, E34/E32 vented rears
Minimum wheel size: 15” wheels front and rear
Stage 6: E28 M5/ E24 M6 fronts, E34/E32 vented rears
Minimum wheel size: TRX, only *some* 15”, 16” wheels front; 15” wheels rear
Stage 7: E34 US M5/US 540i Sport front and rear
Minimum wheel size: some 16” wheels front; 15” wheels rear
Stage 8: E31 front, E34/E32 vented rears
Minimum wheel size: some 16” wheels front; 15” wheels rear
Stage 9: E34 Euro, E31 850CSi Euro (Nurburgring brakes)
Minimum wheel size: 17” wheels front; 16” wheels rear

Climate Case - #Project_91_318i

We had the climate case out to install the carpet, so I went through the case to see if anything was bad in it.



We found that the fresh-air flaps were broken. Previously repaired, the JB weld din't hold.



Also, it looks like the blower had broken at some time, and the squirrel cage melted a hole through the case.

The melted case dripped into the evaporator core and gooped it all up.

So when it was all said and done, the original case was wasted. Time to go to the wrecking yard and get a different one.





"New" Case - went to Bavarian Auto Recycling and got another complete climate case.

This case looked really good. It was complete, except for the cut wiring harness and control cables which were good on our case. I thought it would be a simple case of swapping everything over. The problem came when I tried to remove the wires that go to the blower and the resistor. I could not get them out of the case and had to cut and solder the old wiring to the new case's wiring.

This "new" case also had a recently replaced heater core and heater valve, which is a plus. But I had to put the aluminum tubes from our case on this, since the ends had started to corrode.






I also stepped up and bought new gaskets to seal the case back into the car. $50.00 for the 2 foam gaskets.

Also, when we swapped the carpet, we ripped the drain tubes. So we bought new ones ($27.00) A good move overall. We won't have to worry about it leaking back into the car.

The new case installed.

So with the case installed, I hope to put all the new hoses on the engine and see if this thing runs. We need to figure out if we are going to keep the used motor, rebuld it or swap something bigger into it. I would prefer to keep the 4cyl M42 engine for now. I think this would be best for a 16 year old to learn to drive with. We can always go bigger later. Plus the gas mileage will be better for now. My hope is the motor is good and it was just all the rotted hoses that were causing the problems.

I know we are kinda doing things in a weird order, but the car stunk so bad I wanted to get the interior out and swapped before the rain starts. We have all the interior now, so while I figure out the engine, the Boy can work on putting the interior back together.

We have 97 323i E36 4dr seats (Black Vinyl) and 88 325ix rear seats (Black Leather) with headrests and armrest. We have another dash (no cracks) and climate controls (no broken switches). Still need some different black door panels.

Oh and we have cleaned out the trunk and got different carpet. I'll post some pics later.

Replacing the Carpet - #Project_91_318i

So, with the interior gutted, today we spent time pulling the nasty dash and the climate case out to allow us to install the "new" (new to us) carpet in one piece. We could have cut around the climate case, but I did that on the last E30 and I didn't care for the fit/finish. Plus I'd like the change the heater core and make sure the blower works. There was some mods made to the climate wiring and we needed to replace the dash anyway. The heater case is 6 bolts once the dash is out.

Dash out

I think we will pull the airbag column and install a non-airbag one.

Nasty M42 motor. Supposedly it only has 40lbs of compression.

The old dash. Lots of cracks. Had a aftermarket cruise control glued into it. Cut harness. What a mess.

Climate case out. 6 bolts. Pretty easy once the dash is out!!

Carpet installed. Quite a challenge to get it up to the front, under the peddles and around the column. Glad it's done. Now to look at that climate case.....

Resetting E30 OBC

In order to reset the OBC you need a paper clip or a pen. Stick the paper clip in to the small hole next to the number one in the bottom right corner. Press the appropriate buttons along the bottom to change the time. 1000, 100, 10, 1

You need to press the 1000 button to go from am to pm.

Pressing the AVG MPG button will change from metric to US gal.

Press set-res when done.

FYI - if you light is out, there is a light bar on the left side of the unit. You will need to completely remove the OBC to change this. I believe it's about $35-45 for a new light bar.

Approved oils for BMW transmission

Got this off the ZF website. These are their approved oils and compatability.