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1984 633CSi Rises again!

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sansouci
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Re: 1984 633CSi Rises again!

Postby sansouci » Sun Apr 30, 2017 7:10 pm

Song
Can you write up a list of the proper disassembly and reassembly sequence?
Ken
Sansouci
84 E24 633Csi Auto, Bronzit/PearlBeige 6997510
93 E32 740il M60 Auto, Alpenweis/Ultramarine
60 535i M30 5-speed Green/Beige (crushed)
71 240Z 4-speed White/Blue (rusty & sold)
65 396 Chevelle 4-speed, Marina Blue/Black (stolen)
 

songzunhuang
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Re: 1984 633CSi Rises again!

Postby songzunhuang » Mon May 08, 2017 6:17 am

sansouci wrote:Song
Can you write up a list of the proper disassembly and reassembly sequence?
Ken


I think I can greatly simplify this by showing a picture. Bottom line is, do not worry about the things circled in red.
Remove the bottom pivoting bolts, hose connections and then remove the bolts in yellow. The compressor will drop out.
IMG_1597.JPG
Don't bother with the things circled in red.
IMG_1597.JPG (198.55 KiB) Viewed 368 times


I had tried in vain to remove the items circled in red and it just caused problems. In fact, I had the reassemble those pieces before the compressor would drop out. It was a major pain as it's tight in there.
-----
Song Huang
1984 633CSi
Last 7 of VIN: 6997383
 

songzunhuang
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Window gap on passenger side - fixed.

Postby songzunhuang » Mon May 08, 2017 6:25 am

So I was driving from the airport the other day and noticed that my passenger side window had a lot more wind noice then usual. There was a gap and the window wasn't closing. I could manually move the window glass up and down about 1/2" to 1" inch! This was most annoying. So this weekend I got a change to take a quick look.

In the picture below, you can see that there's a gap between the window glass and the rubber guide. The glass is supposed to go up until the top of the rubber guide is about flush with the glass.
IMG_1896.JPG
Note the gap in the red circle?
IMG_1896.JPG (102.65 KiB) Viewed 367 times


After removing the door panel, imagine my surprise to see that every bolt that secured the window regulator had fallen out! All three bolts were just sitting there, still in the approximate vicinity due to the plastic moisture barrier. Thank goodness for the plastic. In the picture below, you can see two of the bolts that had fallen out and was resting against the plastic.
IMG_1895.JPG
I am glad the plastic caught these fallen bolts.
IMG_1895.JPG (147.02 KiB) Viewed 367 times


It was a simple matter to re-fasten these 3 x bolts with 10mm heads in order to get everything working again. The third bolt is to the right of the picture. I didn't take a picture of that 3rd bolt. This was an easy fix. I need more easy fixes.

The next post about the new A/C compressor will illustrate my point. This A/C is not an easy fix...
Last edited by songzunhuang on Mon May 08, 2017 7:58 am, edited 3 times in total.
-----

Song Huang

1984 633CSi

Last 7 of VIN: 6997383
 

songzunhuang
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Sanden Compressor & Bracket

Postby songzunhuang » Mon May 08, 2017 7:51 am

So I tried to get my replacement compressor test fitted to the custom brackets today. I got some bolts at a place called "Global Metric" in San Mateo and thought I had what was needed to get this "dry fitted". Alas, it was not to be. This was a bit more difficult than I anticipated.

It all started with modifying the aluminum bracket to fit the new compressor and bolt. I got a 10mm x 125mm bolt. I wanted a 10 grade, but then only had 8.8. I figured for a pivot and since the bolt was so hefty, this shouldn't be an issue. I also got assorted washers and a locknut with a nylon insert. I hope the temperatures in this area doesn't compromise the nylon lock. Ok, that was a no sequiter.

First I had to drill out the holes in the bracket for the larger 10mm bolt. I did this in three stages of increasing larger drill bits. I wanted it to be a snug fit and smooth hole.
Drill.png
Drilling out the bracket for a 10mm bolt.
Drill.png (1.13 MiB) Viewed 361 times


After drilling the hole, I realized that the bolt head wasn't going to clear no matter which side I came from. I recall seeing another thread where they had to cut out a chunk of the aluminum to clear the bolt. Well, now I know why. I did the same thing so that I could push the bolt from back to front.
Notch.png
Notch to clear the bolt head.
Notch.png (910.82 KiB) Viewed 361 times


After finally getting the bolt through, I realized that I was going to need a few more spacers. As you can see from the picture (yeah, the arrows got messed up when I resized the picture. Weird) I will need a washer on the left, but a much larger spacer on the right. It looks like I will need to get back to this after I figure out a way to locate a bolt sleeve or something similar.
Spacers Needed.png
Need spacers on both sides.
Spacers Needed.png (1.27 MiB) Viewed 361 times


Finally we move down to the bottom of the bracket. You can see how I positioned the custom metal units onto the adjustable u-bracket. I thought that the custom metal units were supposed to be inside the "U" shaped piece. Well, it wasn't going to line up. I had to place one on the outside and one on the inside of the u-shaped adjustable piece.
Spaces.png
Washers and bolts to space thing correctly.
Spaces.png (1022.91 KiB) Viewed 361 times


I still think I need to place a spacer inside the "u-bracket"; Otherwise as I tighten the adjustment bolt, the U-shaped unit will just deform. That doesn't seem right. Also, the bolt with the adjustments is a bit short. I think I need about 5-10mm more length. I hope I can find that carriage bolt. I measured the new assembly from the bracket mounting hold to the pulley where the belt goes. With the spacing you see here, I think I will be really close (if not spot on) in alignment. I'll know when I finally crawl under the car and put all this together. Alas, I will have to wait for another day as I ran out of time.

I haven't even gotten to the condenser yet, but a plan for that is coming together. It's got a lot of rivets and angled aluminum. More on that later.
-----

Song Huang

1984 633CSi

Last 7 of VIN: 6997383
 

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hornhospital
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Re: 1984 633CSi Rises again!

Postby hornhospital » Mon May 08, 2017 8:00 am

Song, small diameter electrical conduit works well for spacer material. Easily cut with a hacksaw.
Ken Kanne
'84 633CSi "Sylvia"; '85 635CSi "Katja";'87 325is "Odette"; '93 325is "Elvira"; '95 318is "Bebe",dead, for sale as track car
 

songzunhuang
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Re: 1984 633CSi Rises again!

Postby songzunhuang » Mon May 08, 2017 4:52 pm

hornhospital wrote:Song, small diameter electrical conduit works well for spacer material. Easily cut with a hacksaw.

Great to know! I was considering overkill by going to a machine shop to have it milled. Your idea sounds a lot more budget friendly.
-----

Song Huang

1984 633CSi

Last 7 of VIN: 6997383
 

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Re: 1984 633CSi Rises again!

Postby tschultz » Tue May 09, 2017 1:03 am

Great work Song!
 

songzunhuang
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Replaced Intake Tube

Postby songzunhuang » Fri May 12, 2017 6:31 pm

While taking apart my A/C pieces I had to remove the air intake tube. I noticed that it was cracked on the underside and around the MAF unit. Although this isn't something that was creating any issues with how the motor ran, the OCD side of me decided to replace it anyway. Hey, it was easy to do and made me feel better.

Intake Tube.png
Replacement intake at the bottom.
Intake Tube.png (1.33 MiB) Viewed 283 times


I guess the only regret is that I didn't use OEM BMW part so there's no nice BMW logo molded into the tube. Oh well.

Oh, and the car doesn't run any different. :wink:
-----

Song Huang

1984 633CSi

Last 7 of VIN: 6997383
 

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tschultz
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Re: 1984 633CSi Rises again!

Postby tschultz » Sat May 13, 2017 3:29 am

It is known as Air Flow Meter (or AFM), not a MAF (MASS AIR FLOW).

At some point the cracks can cause issues but always good to eliminate failing parts before they cause problems.
 

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Sanden Compressor Installed

Postby songzunhuang » Mon May 15, 2017 7:00 am

Well, we made some progress today. I was able to create a spacer for the lower bracket and install the complete unit on the engine, install the belt and then start the car and check the alignment. I'm happy to say that all ended well. I had to remove the unit again as I still need to figure out a spacer for the top pivot bolt.

I got a 1/2" diameter x 3" pipe nipple for the spacer of the lower bolt. I had to grind about 1/8" to get it to fit perfectly.
Pipe Nipple.png
1/2" x 3 inch pipe nipple worked very well.
Pipe Nipple.png (826.53 KiB) Viewed 247 times


Here is the pipe installed in the lower adjustable bracket.
Half Inch Pipe.png
It fits perfectly around a 8mm bolt.
Half Inch Pipe.png (1.08 MiB) Viewed 247 times


Here is the complete unit installed on the engine. There are so many parts to this assembly that I found it easier to install it completely assembled. Next time, I'll use a jack. It's heavy holding the unit with one hand while trying to get the mounting bolts installed.
Comp Installed.png
All the various bits installed on the engine.
Comp Installed.png (805.85 KiB) Viewed 247 times


The pulley on the engine is about a few sixteeths out of alignment, with the compressor, but I think it'll work given that this uses a V-belt. The adjustable bracket made the original AC compressor belt easy to install! That was a nice outcome.
Here's a link to a YouTube video of the entire thing installed and with the motor running. The alignment doesn't seem to cause issues. I'm going to give it a try.

https://www.youtube.com/watch?v=J29nmiaujfE

Here's a bit longer video with a wider viewpoint.
https://photos.google.com/search/_tv_video/photo/AF1QipPI8_QbrmAVUlDisZdnQaA9VSVxiI9FuMj6OUgh
Last edited by songzunhuang on Mon May 15, 2017 7:41 am, edited 1 time in total.
-----

Song Huang

1984 633CSi

Last 7 of VIN: 6997383
 

songzunhuang
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Fitting a parallel flow condenser

Postby songzunhuang » Mon May 15, 2017 7:21 am

Today, I spent some time scratching my head about how to mount the new condenser and fashion brackets to fit the car. The first order of business was to make a template from the old condenser so that after I take everything apart, I can still figure out how to link everything up. I did this on a piece of cardboard that the new condenser came in.

After making the template, I drilled out all the rivets to prepare the parts for mounting in the new condenser. I had to cut off about 2" of the left side to clear the mounts and pipes on the new condenser.
Drill out rivets.png
drill out 4 rivets to free the top.
Drill out rivets.png (757.61 KiB) Viewed 245 times


Here all the parts taken from the old unit laid on top of the new unit. The top will be installed with a aluminum angle bracket and rivets. The sides will be fastened with some angled steel and more rivets.
Test fit.png
Here's how everything will be arranged to mount the fan.
Test fit.png (962.95 KiB) Viewed 245 times


Of course I had to pretty things upon a bit. I steel brushed and then painted the parts with some engine paint.
BlackPaint.png
Gotta make it look good and stop corrosion while I am at it.
BlackPaint.png (958.02 KiB) Viewed 245 times


Finally the bottom bracket will be quite tricky. I used some angled aluminum that I tool off an old bathroom shower door mount. Part of it will need to fit inside the mounting rails of the new condenser. The other parts will need to be notched and then drilled to match the template.
Bottom Bracket.png
All marked up and ready to fabricate.
Bottom Bracket.png (644.57 KiB) Viewed 245 times


I ran of time to work on this today but I have a really good idea of how this will all fit together now. More next weekend. I can feel it getting close. Now, I'm thinking about the hoses.
-----

Song Huang

1984 633CSi

Last 7 of VIN: 6997383
 

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sansouci
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Re: 1984 633CSi Rises again!

Postby sansouci » Mon May 15, 2017 5:48 pm

Song,
1) When do you find the time to do this? All I've got are "honey-do's"
2) I am following along as the A/C needs to work for me this summer in NYC
3) I guess I'd have gone with a Flex-a-lite or equivalent. I think Da_Hose had a post on converting his fan set up. I think it was called The Best Electric Cooling Fan Set Up (or something like that)
4) What's the P/n for the compressor mount you used?

Keep up the good work.
Last edited by sansouci on Fri May 19, 2017 8:14 pm, edited 2 times in total.
Sansouci
84 E24 633Csi Auto, Bronzit/PearlBeige 6997510
93 E32 740il M60 Auto, Alpenweis/Ultramarine
60 535i M30 5-speed Green/Beige (crushed)
71 240Z 4-speed White/Blue (rusty & sold)
65 396 Chevelle 4-speed, Marina Blue/Black (stolen)
 

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Re: 1984 633CSi Rises again!

Postby dwcains » Tue May 16, 2017 3:25 am

Here's the compressor mount, but you need some other parts, too, e.g. the adjustment bracket and nut/bolt, and those custom-made Sanden adapters,

https://www.ecstuning.com/b-genuine-bmw-parts/bracket/64521284953/

I sent the mount to Song, and I found it on eBay for ~$45 IIRC. I'd look for another used one, considering the new cost, and that you need the other bits with it. The whole assembly is on this page:

http://www.realoem.com/bmw/enUS/showparts?id=5371-EUR-10-1984-E24-BMW-635CSi&diagId=64_0427
Dean
Lutz, FL

'85 635 CSi Euro #9402254
'87 Spider Veloce
'92 Spider Veloce
'08 350Z

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sansouci
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Re: 1984 633CSi Rises again!

Postby sansouci » Wed May 17, 2017 9:30 pm

Dean,
I've got the two custom cut adapters from a group buy a while ago in preparation for this project. Thanks for the realoem page and the heads up on the mount.

Dean- this is on fleabay and the p/n doesn't match. But could it work?
http://www.ebay.com/itm/311703065833?_t ... #vi-ilComp

--Ken
Sansouci
84 E24 633Csi Auto, Bronzit/PearlBeige 6997510
93 E32 740il M60 Auto, Alpenweis/Ultramarine
60 535i M30 5-speed Green/Beige (crushed)
71 240Z 4-speed White/Blue (rusty & sold)
65 396 Chevelle 4-speed, Marina Blue/Black (stolen)
 

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dwcains
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Re: 1984 633CSi Rises again!

Postby dwcains » Thu May 18, 2017 12:37 am

Maybe you can get a measurement and compare with Song's. I can't look at mine, as I'm in the hospital,again, for an unknown term, again. :cry:
Dean
Lutz, FL

'85 635 CSi Euro #9402254
'87 Spider Veloce
'92 Spider Veloce
'08 350Z

Image
 

songzunhuang
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Re: 1984 633CSi Rises again!

Postby songzunhuang » Thu May 18, 2017 5:30 pm

sansouci wrote:Dean,
I've got the two custom cut adapters from a group buy a while ago in preparation for this project. Thanks for the realoem page and the heads up on the mount.

Dean- this is on fleabay and the p/n doesn't match. But could it work?
http://www.ebay.com/itm/311703065833?_t ... #vi-ilComp

--Ken


Hey, I'd be glad to pay it forward as I have a spare unit for the bottom adjustable mount. Dwcain gave me a mount, I'd be glad to give you the adjustable bracket. Here's the brackets side by side. They have the same width so it should work just fine for you.
Screen Shot 2017-05-18 at 10.28.55 AM.png
I used the one on the right. Ken, you can have the one on the left.
Screen Shot 2017-05-18 at 10.28.55 AM.png (631.3 KiB) Viewed 133 times


I ended up using the unit with a wider adjustment range, but to tell you the truth, I don't think. I needed that. I'm using the belt that was on there and to get the belt on, I have to go to the shortest setting and then when I tighten, it's only about 1/2 way through the adjustment. So although the spare unit I have doesn't have as much adjustment, it'll work fine. Hey, it's free.

So if you want it, just PM me. It's also got the bolt and adjustment nut. I noticed the one on eBay does not.
-----

Song Huang

1984 633CSi

Last 7 of VIN: 6997383
 

songzunhuang
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Perfect Fit for Sanden Compressor

Postby songzunhuang » Tue May 23, 2017 5:08 am

So this weekend I was able to perfect the mount for the Sanden compressor. After a bit of fabrication, I still had a few areas where there were gaps to fill. I finally found the proper pieces and cut it all to size.

First, I had a gap to fill between the aluminum compressor mounting bracket and the actual wing of the compressor. I needed something that a 10mm bolt could pass through. After much searching, I came across a Carbon Steel Spanner Bushing 42mm Long -- 12mm OD x 10mm ID. It was $5 on Amazon.
Spacer.png
This is close to perfect.
Spacer.png (643.6 KiB) Viewed 101 times


OK, the length wasn't quite right so I had to cut it to size and grind it to the exact spec. I also discovered that I had to drill out the hole a bit as it was a bit snug for the bolt.
Cut to Size.png
It was just under 30mm in length.
Cut to Size.png (989.68 KiB) Viewed 101 times


While I was at it, I cut the bolt to eliminate a spacer on the other side and achieve an better overall fit.
MOre Cuts.png
The bolt and the spacer now fit.
MOre Cuts.png (739.43 KiB) Viewed 101 times


After I assembled it all, it was aligned, tight and perfect. This assembly is finally ready to go into the car.
Perfect FIt.png
All pieces in place and ready to mount.
Perfect FIt.png (1.11 MiB) Viewed 101 times


So next weekend, we turn our attention to the condenser. I've got some ideas there too.
-----

Song Huang

1984 633CSi

Last 7 of VIN: 6997383
 


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