Introducing FAQ Memberships 04/17/2017I would like to introduce everyone to the FAQ memberships. A fun way to fund the site and to contribute for those who are interested. Everyone starts as a Solex Member. This membership is free and not much visible is changing (I limited the personal message storage to 150). Kugelfischer membership. As a reward for your donation of $20.02 per year, you will not see any external advertisements, the site will look cleaner and run a bit faster. You will also get a couple of BMW 2002 FAQ Stickers. Turbo Membership. As a reward for your donation of $50.02, you will not see any external advertisements, the site will look cleaner and run a bit faster. You will also get unlimited Personal Message storage, ability to create Private and Restricted Photo Albums. You will also get a couple of BMW 2002 FAQ Stickers and a Bottle Opener. Alpina Membership. As a reward for your donation of $100.02 per year, you will not see any external advertisements, the site will look cleaner and run a bit faster. You will also get unlimited Personal Message storage, ability to create Private and Restricted Photo Albums, and an ability to upload Movies to the gallery. You will also get a couple of BMW 2002 FAQ Stickers, a Bottle Opener, and discounts on our accessories at the store. There is also a fancy title that comes with each membership.
I was finally in a position to set an entire day aside to work on the 2002 today. (Well, really about 4 hours.) The first item on the agenda was removing the reactor/exhaust manifold and installing a new header as part of removing the emissions controls. I will try to make an article out of this emissions control removal process. But not today because, you know, gauntlets.
Today I discovered 3 things:
1) The Previous owner or his mechanic tried to remove the manifold/reactor before. 2 of the 4 upper bolts were actually loose and all 4 lower bolts that you access from under the car were stripped. I should have known something was up when all of the nuts to the heat shields came off so easily.
2) You can't get a pair of vice-grips onto the nuts under the manifold because there isn't enough room. Why? Because my car has A/C and the huge compressor sits under the manifold.
3) You can't remove the compressor without removing a lot of other components. The compressor bolts are not accessible and the compressor bracket bolts attach immediately behind the fan. A couple of compressor bracket bolts were missing, meaning I'm following in the PO's (or his bad mechanic's) footsteps.
4) Normally, to get to the water pump for example, you can pull the radiator, remove the grill and go through the front of the car with a long ratchet extension. I thought maybe I'd do this since I have to replace the water pump anyway. Nope, the A/C condenser and an auxiliary fan sit in front of the radiator.
So one way or another, I'm going to have to pretty much remove the entire A/C system from the car before I can finish with the manifold/reactor/header.
Oh, and I think I mentioned earlier how bad the fluid leaks are. I spent a full day cleaning the engine from above, but I completely neglected to get underneath. There is anywhere from 1/8 of an inch to 1/2 of an inch of congealed oil covering the bottom half of the engine and all of the front suspension components. Now it looks like I'm going to have to clean everything by hand and I won't know where the leaks are until I get a few more parts off the car and the block cleaned up.
Here's a shot showing the A/C compressor and the lack of space to get anything bigger than a box wrench into the space by the manifold. No way a pair of Vice Grips will fit up there. Note the missing bracket bolt from somebody's prior attempt to remove it.
Here are the compressor mounting bolts up by the fan.
Here's the A/C condenser and auxiliary fan in front of the radiator.
And this image pretty much sums up how far I got today. Heat shields off, a couple of connections off, that's it. I put the plug wires back on to avoid damaging them.
So I did not get as far as I had hoped today. That's pretty normal. There is one small silver lining to all this. While I was under the car, I found the Weber air cleaner cover C-clip that the previous owner lost a long time ago. It was embedded in about 1/4 inch of oil sludge. If the engine had been clean, this would have bounced out ages ago.
Havent actually posted in ages, not because i havent been working on the car, its the contrary, ive been there as much as possible evening and weekend and really working my socks off to get it finished before its just too cold to work on it. since my last post ive managed to install the new hardlines up front for the brakes, the new flexis to the calipers. fitted all the braking bits and got the system ready to receive the re-conditioned Master Cylinder.
i should have taken some before pictures of the M/C however here is an after shot
this was an original part which was re-conditioned by a company in england. really happy with how it came out and the turn around was really quick and reasonably priced.
fitted up went in like a dream
ive also ordered all the service bits for the car so i can fill it with nice new fluids before we start it up
note: the oil filter is wrong! ive sent them an email and i am getting a new one soon
slight disaster with the servo the bleed nipple sheeered off inside the body, going to have to drill it out and replace before i can bleed it all.
:'( makes me sad, was so close to getting it done today.
on a positive note, getting closer to a final decision with the center console, and even finished the speaker pods to give me some back pressure on the front mids and to stop any phasing of the speakers.
made from heavy duty cardboard tube and filled with sound insulation to dampen any vibrations
a final shot of the console mocked up.
will probably change the orientation of the ashtray and button holder as there is some depth issues with the ash tray. the whole console will eventually be flocked in black to help it tie in with the interior of the car.
this week: hopefully will get back to the garage and get the pesky broken nipple out and get it fitted back up, a good thing which has come out of this, is it gives me a chance to clean the servos and paint them before they go back in. its just more and more things to do before the january deadline
wish me luck
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