Maintenance

2019 MOT – handbrake failure and fix

So the MOT tester is a beast of a man and ripped both handbrake cables clean off the mounts! Better it failed here than in an emergancy though.

The orginal handbrake adjusters are bolts with the head of a bolt chopped, the end drilled with the lathe and a recess to capture the shorted handbrake cable with a spot of weld.

As the handbrake cables were now shorter than before the bolts were too short. These were extended by chopping the machines part off the old bolt and welded on to a new bolt making it longer. The recess needed drilling out again to remove old handbrake cable.

If this fails again it will need new handbrake cables.

The torn ends zipped tie down to make them easier to clean up for welding

Cables welded back on

Finally mounted back into the handbrake handle and adjusted. Hand brake retested with better results than the rear brakes!

The car was also failed on emission first time round as the machine was set wrong. HC limit for an 88 engine is 1200, it comes in around 650 – which as been the same for a numbr of years now. They incorrectly wanted to see less than 18 – keep an eye for that one, page 12 of this document is useful if you need paperwork: https://assets.publishing.service.gov.uk/government/uploads/system/uploads/attachment_data/file/676700/in-service-exhaust-emission-standards-for-road-vehicles-19th-edition.pdf

Engine Work

Coolant flush and refresh

This drain plug has been leaking forever, the drain part is reverse thread and normal thread into the radiator. The thread into the radiator needed more PTFE.

Due to topping up with water over the last couple years the coolant was starting to get hotter than normal when the engine was pushed. With the new coolant G48 with suitable BMW specification the needle stays steady on 80ºC when pushed hard. When testing on idle at a standstill the fan kits in at 88ºC and comes down again nicely to the low 80’s. 

Chassis

Rear brake pads

I fitted ATE brake pads to the front some time ago, they bite much better than the Jurid ones and generally feel better. 

The rear was still on Jurid and as they’ll probably never wear out I thought I’d swap them over to ATE so they match all around.

Used the opportunity to check and retorque the H&R spacers at the rear.

Need to repaint this calliper at some point, the silver never was a good choice, the front is already black.

Now labelled ATE Classic, 1988 donor!

Solid disks on from the donor E30 325i, the front is vented.

All back together again

 

Otherside done too, these Ryobi lights are really handy – even when working on the driveway.

 

 

Engine Work

Adjusting valve clearances and a new rocker gasket

Fix the jump leads – no continuity = useless jump leads. The copper was crimped and cut straight through at the factory. Trimmed and now soldered – much better.

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Inside the rocker cover still looking very clean. Adjusted all the valve gaps to 0.25mm, glad there are only 12 valves to do! Most needed a little tweak. Also gave the oil spray bar a good clean out with brake cleaner while the cover was off.

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The rocker gasket was a bit very second hand, luckily a local parts shop had one in stock.

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Engine Work

Service

Service time!

New oil – fully synthetic ester

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Managed to avoid spilling anything on the ground for a change!

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Being able to take the side off the engine bay really makes filter swaps easy!

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Also done is 6 new spark plugs (they’re pretty cheap so why not!)

Found a minor vacuum leak so the idle is much better now.