1987 635 euro spec in the deserts of the UAE

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Desert635
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Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

Got the radiator out today and flushed out all the crud from the block, going to try and get an all aluminium radiator fabbed up, replace the temp switch and fix the wiring for the fan switch to get it to activate properly.we'll also pull out the battery and clean up the area around and try to tidy up all the wiring in the engine bay as well.

While the battery is out we'll try to get a battery tray and mount fabbed up as of yet the battery is just sitting loose in the engine bay

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1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

Dropped off the radiator at serck services today and they should have a new one ready for me by Wednesday morning I'll probably still be waiting for parts to arrive from the US by then but it's just the fan switch and some other small parts so we'll be able to mount the new radiator and get her running again
1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

Still have a few days left for the parts to arrive, cleaned off some rust and painted the areas to prevent more rust.

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Radiator should be back in next week when the parts arrive and once she's running take a long test drive with the 179 dme and see how it responds, might do the same 240km run and run one dme one way and the other on the way back to see how they're performing. Would there be a reason for the engine to idle slightly more rough and rich with one ecu and completely fine on the other?
1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

So we got the radiator back in with a new fan switch and we were meant to flush the radiator and fill it up.

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I knew the heater didn't work and the car has an aftermarket ac compressor installed so I wanted to have a slight looksie behind the panels before diagnosing where the issue was and see if anything has beeen tanpered with.

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What went from a peek rolled on to a full dash removal... Huge thanks to Ozibimmer as I used his guide and it was a major help.

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I have my hands on a parts car and just managed to remove the ac panel off of that, hopefully I'll be able to strip that dash out tomorrow and compare the wiring and parts from that and off of the etk to see what is missing.
1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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sansouci
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Re: 1987 635 euro spec in the deserts of the UAE

Post by sansouci »

Oh boy! Looks like mission creep. Best of luck.
Sansouci
84 E24 633Csi Auto, Bronzit/PearlBeige 6997510
93 E32 740il M60 Auto, Alpenweis/Ultramarine
60 528i 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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Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

sansouci wrote:Oh boy! Looks like mission creep. Best of luck.
Thanks, this time it might be in for the long haul, aside from the ac and wiring might as well get the interior re-done, put a decent sound system in and do the manual swap since it's already stripped down.

The parts car got a little attention as well.

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1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

Now we're cleaning up and refurbishing the ac system, have the ac and heater blower out, taken apart and cleaned. Took the condenser and evaporator from the donor car, might be using the wiring harness as well as the blower switch and temp control unit.

The ac compressor will be getting fixed up and we'll swap that over with the ac lines. Still need to finish up the wiring as well as swap the fuse box top end.

It feels like all the time we're spending is just to reverse and fix the po's hack jobs.

Many more things on the list such as refurbishing the recaro seats, swap headlights and chrome trim from donor car and the list goes on... Haha jumped into all of this because the heater didn't work

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1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

Baby steps, Saturday will clean the whole area by the firewall so we can put the ducts back in on Sunday. Heater blower motor was jammed, after cleaning up it managed to spin but on one side has a bushing stuck and is spinning it along each time it's activated. Ac compressor needs to be opened and cleaned to make sure it's working properly, hoping we can unseize it without a major headache.

Image
1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

Dismantled the compressor and started cleaning all the parts, will do a more thorough cleaning in the coming days, get a new bearing and put it all back together.

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1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

When we were re-assembling the compressor on Wednesday we stripped a bolt in and managed to get it out. Thursday re-tapped the thread and managed to snap the tap off in there and that wouldn't come back out so off to the machine shop to have it drilled out and a new thread tapped in, the bolt I got from them was a bit too short so will get a new one tomorrow.

The gears for the odometer arrived today as well so my friend finished up the work on the instrument cluster cleaned up, re-soldered and reset. Seeing the cluster this clean is really pushing me to get her all ready.

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1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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sansouci
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Re: 1987 635 euro spec in the deserts of the UAE

Post by sansouci »

Would love to see detailed pics on the compressor dis and re-assembly along with parts sources......
Sansouci
84 E24 633Csi Auto, Bronzit/PearlBeige 6997510
93 E32 740il M60 Auto, Alpenweis/Ultramarine
60 528i 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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Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

sansouci wrote:Would love to see detailed pics on the compressor dis and re-assembly along with parts sources......
Sorry it was a very messy job and I didn't manage to take many pictures, just took a couple as a reference on where everything sat.

The o-ring at the top of the shaft was the only thing needing replacement aside from the stripped bolt
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In here the piston sits (which I didn't get any pics of)

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The housing at the bottom of the shaft has vertical slots cut out and rectangular shims are inserted, these slide in and out as the compressor runs. As there was light corrosion and dirt on them for sitting so long this was why the compressor wouldn't spin by hand. We cleaned the corrosion off of them with 2000grit emery paper very lightly until they would slide into their slots effortlessly.
I'll see if we can disassemble the compressor again and get some pictures of everything.

We might be pulling the engine and trans after we strip the interior out to clean everything and send it to paint, there's a whole load of grime and crap trapped in the chassis rails and I'm not sure how we'll be able to get it all out.

Good thing is today I bumped into that elusive 6 series that visited the dealership many moons ago and I never managed to find out it's paint code... Deep sea blue. I can't wait to see how my 6 will look in that
1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

Stripped out the interior on my 6 today, I'm really happy there's no rust to be found. I'm going to try to remove the front bumper headlights and grill and pull the trans out tomorrow but this is if the lifter isn't being used. Saturday we'll come in and try to get the engine out, then we can get the whole interior and engine bay cleaned, send it off for dent repair and painting and hopefully have a manual trans ready by then.

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1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

Got her ready for the weekend, pulled off the mouldings around the windows. Took the exhaust, radiator, lights, grill and bumper out and drained all the fluids. Saturday will be fun.

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1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

Started out pulling off the rear bumper and lights before my friends started arriving. We had all the fluids drained and an engine crane and gearbox stand ready on Thursday and today we just had to disconnect the power steering lines, fuel lines and route the ecu wires out through the firewall and we could drop the trans and engine.

Amazingly it only took 2 hours and an additional hour to clean up and organize/label everything.

Good fun

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1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

Progress so far on the dent work, some very slight rust repairs are to be done before prepping for paint.

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1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

Some more photos

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1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
User avatar
Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

Some progress :D
Interior already got resprayed, the chrome bumpers had some cracks welded and were sent to get re-chromed. I can finally see the light at the end of the tunnel.

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1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

Fresh out the booth, hopefully in a few days time can get started on the wiring then get the interior re-upholstered and finally put her all back together.

While I was waiting for the body shop to be done, a "supposed" friend found a "very clean" in his words euro M88 engine, got it andoes in two days stripped it completely down. Engine oil was burnt, most the wiring was burnt, one camshaft broken, cylinder head pitted and warped and best of all the block had a crack in it. Learnt my lesson on trusting people who are trash.

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1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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Desert635
Posts: 114
Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

Electrical work is getting started now as well as deleting whatever isn't needed. I've removed the self leveling system with the hard lines and reservoirs.

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Today, got the ac lines from the rear removed, as well as the oil cooler lines for the automatic gearbox as they won't be needed for the manual transmission.

I broke off a bolt re-installing the rear axle support bracket yesterday, luckily I managed to get it out easily and replaced all of them with new bolts. Tomorrow I'll be going over all the bolts that weren't already changed, inspect and replace what's necessary.
1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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sharkfan
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Re: 1987 635 euro spec in the deserts of the UAE

Post by sharkfan »

Impressive work and dedication, keep it up.
2001 Alpina B10 V8 Touring (1 of 12 rhd)
1997 Alpina B12 5.7 L (1 of 2 rhd)
1995 Alpina B10 4.6 Touring (1 of 1 rhd)
1985 BMW M635CSi (1 of 524 rhd)
1982 BMW 635CSiA (1 of 100's left from the 1000's made and still valiantly fighting against a rusty grave)
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Desert635
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Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

sharkfan wrote:Impressive work and dedication, keep it up.
Thanks, I feel like this project has already crested the hill and the rest should be all downhill... that's if I don't jinx myself :-#

I'm really thankful for this forum and all the people who have put so much great information, if it wasn't for you guys I would've probably taken her out back and put her down a long time ago
1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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MrE
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Re: 1987 635 euro spec in the deserts of the UAE

Post by MrE »

Fresh out of the booth, that's a beautiful colour Image
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Shipper 01
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Re: 1987 635 euro spec in the deserts of the UAE

Post by Shipper 01 »

Desert635 wrote:
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How heavy is that condenser/heating unit and where was it hiding????? If you want to lighten a car, that's gotta go for sure.
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Desert635
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Joined: Sat May 30, 2015 2:24 pm
Location: United Arab Emirates, Sharjah

Re: 1987 635 euro spec in the deserts of the UAE

Post by Desert635 »

Thanks MrE.

Shipper, that sits behind the blower motor inside the plastic housing, for weight reduction I'd get rid of the metal bumpers and shocks and try to get a full fiber glass spoiler made similar looking to the 3.0 csl that would be look so good.
1987 635CSI Japan Spec
Was: R̶o̶y̶a̶l̶b̶l̶a̶u̶ ̶M̶e̶t̶a̶l̶l̶i̶c̶ ̶(̶1̶8̶9̶)̶
Now: Tiefseeblau Metallic (A76)

VIN: 0766354
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