1988 635csi "Bring Her Back to Life"

Document your Sixer project here.

Moderators: GRNSHRK, ron, bfons

juiceof07
Posts: 87
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

1988 635csi "Bring Her Back to Life"

Post by juiceof07 »

Hey Everyone,

I purchased this Shark back in November and Im definitely ready to bring her back to life. I was looking for a classic BMW to work on and I came across this one on craigslist for $600. I was so excited when I purchased it even though the interior is in terrible condition, I was missing a passenger side front fender and the brakes didn't function. However the engine ran and ran quite smoothly I might add. So I got it towed to the house and I have been tinkering with it since. I figured it wouldn't hurt if I brought you guys along for the refresh journey. I've never restored a car but my 98 540i/6 has forcefully turned me into a mechanic..so on to the next level. Im not very familiar with the in's and out's of this car but I'm learning more about it every day through this forum and the extremely helpful people on it. Here are my plans and some pics!!!!

Complete Interior Redone
5spd Manual Swap
Paint and Body Work
Complete Suspension Redone
Engine Bay Cleaning and Restoration

High Priority Parts:
e21 Recaro Seats (Purchased)
e24 Tail Lights (Purchased)

Hope you guys enjoy! If you all have any wisdom to pass on down please do. It would be greatly appreciated! Thanks!
Attachments
IMG_1087.jpg
IMG_1087.jpg (1.47 MiB) Viewed 13460 times
IMG_1093.jpg
IMG_1093.jpg (1.31 MiB) Viewed 13460 times
IMG_1082.jpg
IMG_1082.jpg (1.79 MiB) Viewed 13460 times
IMG_1085 (1).jpg
IMG_1085 (1).jpg (1.63 MiB) Viewed 13460 times
Last edited by juiceof07 on Wed Jun 22, 2016 6:57 pm, edited 3 times in total.
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725
juiceof07
Posts: 87
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 »

More Pics!
Attachments
IMG_0752.jpg
IMG_0752.jpg (1.62 MiB) Viewed 13460 times
IMG_1083.jpg
IMG_1083.jpg (1.48 MiB) Viewed 13460 times
IMG_1086.jpg
IMG_1086.jpg (1.54 MiB) Viewed 13460 times
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725
MSGGrunt
Posts: 520
Joined: Fri May 15, 2015 4:43 pm
Location: Western, MA USA

Re: 1988 635csi "Bring Her Back to Life"

Post by MSGGrunt »

Nice to see one saved instead of parted out.
juiceof07
Posts: 87
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 »

The 1st Day!
Attachments
IMG_0585.JPG
IMG_0585.JPG (1.83 MiB) Viewed 13431 times
IMG_0586.JPG
IMG_0586.JPG (1.74 MiB) Viewed 13431 times
IMG_0587.JPG
IMG_0587.JPG (1.39 MiB) Viewed 13431 times
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725
juiceof07
Posts: 87
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Got some Problems!

Post by juiceof07 »

"Parasitic Battery Draw"
Hey guys,
I can't seem to keep the battery charged for more than 8-9 hours. There is a draw on Fuse 21 which is the glove box, interior light, trunk light, etc, etc. There is no radio installed, the OBC doesn't turn off even when the car is off, glove switch and trunk light are functioning correctly. I have no idea what "instruments" are and how to check if the draw is coming from there. I searched some topics with similar issues and I decided to check my voltage regulator.... :shock: :shock: :shock: ...the two contacts were down to almost nothing! I just ordered one so hopefully this helps. I don't understand how this would take care of the battery drain though.. :-k :-k . Any wisdom or light on this issue would be truly helpful! Thanks Guys!

The Voltage Regulator... :shock: :shock: :shock:
Image

"Squealing on Start and Acceleration"
When car is running there is a massive squealing sound upon acceleration coming from the alternator. Is this also due to the voltage regulator?

"Mystery Wire"
Can someone please tell me what that wire is towards the top that is headed into the firewall? It was just randomly laying around with no connection on the end. Thanks!

Image

Thanks alot guys!
Attachments
IMG_1096.jpg
IMG_1096.jpg (973.21 KiB) Viewed 13393 times
IMG_1097.jpg
IMG_1097.jpg (1.58 MiB) Viewed 13393 times
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725
juiceof07
Posts: 87
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 »

Hey guys! Did a little investigating and it seems that the wire mystery wire is connected to 5A fuse and some other silver cylinder with 5V going to it! Here are some photos! Anyone have any experience with this? I'm thinking it's an aftermarket alarm system of some sort.
Attachments
Silver Cylinder with 5V going to it.
Silver Cylinder with 5V going to it.
image.jpeg (1.52 MiB) Viewed 13327 times
5A Fuse.
5A Fuse.
image.jpeg (1.37 MiB) Viewed 13327 times
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725
juiceof07
Posts: 87
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 »

Hey guys,

Been working on the shark and examining the wiring harness. The orange connectors for the abs sensors and the impact sensors are too brittle to handle without crumbling in my hands. I've been searching for a solution and I found these "18AWG Wire Gauge Male Female Plug 2 Pin LED Waterproof Connector Cable Black" on Amazon. Can i just splice the wires and attach these and be good to go? Any help would be greatly appreciated. Thanks!
Attachments
18AWG Wire Gauge Male Female Plug 2 Pin LED Waterproof Connector Cable Black
18AWG Wire Gauge Male Female Plug 2 Pin LED Waterproof Connector Cable Black
Screen Shot 2016-05-11 at 12.26.18 AM.png (299.31 KiB) Viewed 13266 times
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725
User avatar
Ralph in Socal Online
Platinum Member
Platinum Member
Posts: 2746
Joined: Tue Apr 14, 2009 3:32 am
Location: High Desert of SoCal

Re: 1988 635csi "Bring Her Back to Life"

Post by Ralph in Socal »

You have your hands full!! Leave mystery aftermarket wires alone until the car is running well then slowly (one at a time) determine if you can cut it off. Test the car after each wire is cut to make sure there are no negative effects from the cut. This way you can reconnect easily to get the car back into proper function.

Stock mystery wires should be left alone as these cars have connectors for multiple additional options. A loose stock wire is very normal with these cars.

Not sure about your parasitic draw but it seems you have it narrowed down. Best way to check the glove box and trunk lights are to either remove them to make sure they are not your problem or get in the trunk and close it then have someone open it for you. The switches may function properly but the light may not be going off. Sorry but I have no experience with the alternator effects. Hopefully someone else will chime in about the OBC staying live as well. Instruments are the gauges so probably the lighting for the dash.

I applaud your determination. Good Luck and Keep it up.

Ralph
There is a very fine line between "Hobby" and Mental Illness.

85 635csi Zinno Auto
84 528i Euro
83 635 Euro Arktik
81 528i Kastanien 5-speed
88 528e Bronzit (Granpa Car)
86 535i Auto (For Sale)
81 633 csi (retired)
User avatar
dwcains
Posts: 1465
Joined: Sun Sep 14, 2014 6:01 am
Location: Lutz, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by dwcains »

In no particular order - that yellow wire isn't original. May have been for an aftermarket stereo, alarm, etc. Those plugs actually look like a great idea to replace the ABS plugs, nice find. The voltage reg may or may not be OK, but those brushes are gone. If you're handy with solder, you can just swap the brushes, or you can just get a whole new regulator for $30. The alternator noise is likely a bad bearing. Again, you can replace the part, or the whole alternator. As for tracing the current drain, pull the fuses one by one until it stops, and then look at that circuit in the factory manual.

http://wedophones.com/Manuals/BMW/1988% ... Manual.pdf
Dean
Lutz, FL

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

Image
juiceof07
Posts: 87
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 »

Thanks a lot guys! I'm pretty sure the car has an alarm. As soon as I removed the fuse from the socket the doors unlocked. So It's definitely connected. I replaced the voltage regulator and cant really tell the difference... :-k ... but I'm sure its doing its job. Disconnected the OBC and the current draw is significantly less but still existent so I'm gonna pull this alarm system.

The "yellow wire" is actually a vacuum tube of some sort. It heads under the intake. Not sure what its for but it needs to be replaced.
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725
User avatar
dwcains
Posts: 1465
Joined: Sun Sep 14, 2014 6:01 am
Location: Lutz, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by dwcains »

Can't guess why there'd be a vacuum line, as the car already has a vacuum gauge. Maybe it was for a mechanical oil pressure gauge?
Dean
Lutz, FL

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

Image
juiceof07
Posts: 87
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 »

dwcains wrote:Can't guess why there'd be a vacuum line, as the car already has a vacuum gauge. Maybe it was for a mechanical oil pressure gauge?

No clue. Ill take some pics of where the lead ends and post them and that should help.
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725
User avatar
M6smitten
Posts: 748
Joined: Tue Jan 12, 2010 5:08 am
Location: Denver, CO

Re: 1988 635csi "Bring Her Back to Life"

Post by M6smitten »

Keep posting your progress please.
2011 1 Series M
1974 2002 Turbo
1987 M6 (2/87) - Sold
1984 M635CSi (10/84) - Sold
2012 335 xi
2009 328 xi

Image
User avatar
M6smitten
Posts: 748
Joined: Tue Jan 12, 2010 5:08 am
Location: Denver, CO

Re: 1988 635csi "Bring Her Back to Life"

Post by M6smitten »

Keep posting your progress please.
2011 1 Series M
1974 2002 Turbo
1987 M6 (2/87) - Sold
1984 M635CSi (10/84) - Sold
2012 335 xi
2009 328 xi

Image
User avatar
Ralph in Socal Online
Platinum Member
Platinum Member
Posts: 2746
Joined: Tue Apr 14, 2009 3:32 am
Location: High Desert of SoCal

Re: 1988 635csi "Bring Her Back to Life"

Post by Ralph in Socal »

juiceof07 wrote:Thanks a lot guys! I'm pretty sure the car has an alarm. As soon as I removed the fuse from the socket the doors unlocked. So It's definitely connected. I replaced the voltage regulator and cant really tell the difference... :-k ... but I'm sure its doing its job. Disconnected the OBC and the current draw is significantly less but still existent so I'm gonna pull this alarm system.

The "yellow wire" is actually a vacuum tube of some sort. It heads under the intake. Not sure what its for but it needs to be replaced.
Alarm systems usually intercept the Black/Yellow wire coming from the ignition switch and going to the starter. Look for the intercept point under the dash in the wire loom coming from the steering column. Minimize splices on this wire as it's critical to have a strong +12V current signal for the starter.

The vacuum tube is for the Interior Air Temp Sensor that belongs in the underdash panel. It attaches to a nipple on the underside of the intake manifold with a small section of vacuum hose. It is supposed to have a flow restrictor in the section of vacuum hose at the sensor. I may have this backwards but either way there is supposed to be a flow restrictor insert in the hose.

Keep on ...

Ralph
Last edited by Ralph in Socal on Wed May 11, 2016 11:36 pm, edited 1 time in total.
There is a very fine line between "Hobby" and Mental Illness.

85 635csi Zinno Auto
84 528i Euro
83 635 Euro Arktik
81 528i Kastanien 5-speed
88 528e Bronzit (Granpa Car)
86 535i Auto (For Sale)
81 633 csi (retired)
User avatar
dwcains
Posts: 1465
Joined: Sun Sep 14, 2014 6:01 am
Location: Lutz, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by dwcains »

Ralph in Socal wrote:
The vacuum tube is for the Interior Air Temp Sensor that belongs in the underdash panel. It attaches to a nipple on the underside of the intake manifold with a small section of vacuum hose. It is supposed to have a flow restrictor in the section of vacuum hose at the sensor.

Keep on ...

Ralph
On my car the vacuum tube comes into the car somewhere on the passenger side, I think. It's been a while since I've looked that closely, and it's surely not yellow.
Dean
Lutz, FL

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

Image
juiceof07
Posts: 87
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 »

Thanks for all the responses guys! I'll post some progress soon.
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725
juiceof07
Posts: 87
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 »

UPDATES!!

Not a major update but I got a passenger fender, some interior parts that were torn, and the trunk carpet.

I did some more investigating and Im almost 90% sure that the car has an aftermarket alarm system. Im gonna start pulling that out of the car tomorrow! That should clean up some power drain issues!

Also sent rotors to be refinished. Ordering new SS brake lines and all the bushings for the rear subframe. Apparently the previous owner took them all out... :-k . Brakes aren't functioning so hopefully I can get that up and running this week. After all the reading I've done its going to come down to Brake Bomb or Master Cylinder.

Also purchased some rust remover to plunge my calipers in to remove the excessive rust build up. Then I'll coat them with some silver paint that will stand up to the high heat. Here come the pics!
Attachments
Alarm Box2
Alarm Box2
IMG_1151.jpg (1.05 MiB) Viewed 13097 times
Suspected Alarm Box1
Suspected Alarm Box1
IMG_1150.jpg (944.63 KiB) Viewed 13097 times
FENDER!!!
FENDER!!!
IMG_1144.jpg (1.31 MiB) Viewed 13097 times
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725
juiceof07
Posts: 87
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 »

LOOK WHAT I FOUND!!!!

HOF CO Alarm Unit!
Question for you all. Should I cut off all wires that were connected to the alarm as car as I can see or should I just leave them alone?
Attachments
image.jpeg
image.jpeg (1.28 MiB) Viewed 13017 times
image.jpeg
image.jpeg (1.88 MiB) Viewed 13017 times
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725
juiceof07
Posts: 87
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 »

Gutted the Alarm.... 8)
Attachments
image.jpeg
image.jpeg (1.66 MiB) Viewed 13009 times
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725
juiceof07
Posts: 87
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 »

GOT SOME RECARO SEATS!!!
Attachments
rsz_1e24_seats.jpg
rsz_1e24_seats.jpg (73.83 KiB) Viewed 12967 times
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725
User avatar
dwcains
Posts: 1465
Joined: Sun Sep 14, 2014 6:01 am
Location: Lutz, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by dwcains »

Nice. Try this stuff for cleaning them up:

Image

I use in on the cloth seats in my 350Z and it does a great job. Worked on the trunk lining in my 635, too.
Dean
Lutz, FL

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

Image
User avatar
Ralph in Socal Online
Platinum Member
Platinum Member
Posts: 2746
Joined: Tue Apr 14, 2009 3:32 am
Location: High Desert of SoCal

Re: 1988 635csi "Bring Her Back to Life"

Post by Ralph in Socal »

You'll need a set of e24 manual comfort seat rails to bolt the Recaros to. Easiest way to get them in the car without any modifications. They may bolt up to the electric rails you have on hand but they will be a manual/electric hybrid.

One 10mm head bolt at each corner of the seat underside for mounting. Please let the group know which way you make them work for future reference.


Ralph
There is a very fine line between "Hobby" and Mental Illness.

85 635csi Zinno Auto
84 528i Euro
83 635 Euro Arktik
81 528i Kastanien 5-speed
88 528e Bronzit (Granpa Car)
86 535i Auto (For Sale)
81 633 csi (retired)
juiceof07
Posts: 87
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 »

dwcains wrote:Nice. Try this stuff for cleaning them up:

Image

I use in on the cloth seats in my 350Z and it does a great job. Worked on the trunk lining in my 635, too.
Ill pick up a can today! I plan on ordering the kit and getting them wrapped in either "high quality German vinyl" or leather down the line. A couple of the bolsters are gone so im gonna need to replace them. Thoughts on which on to go with?
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725
juiceof07
Posts: 87
Joined: Wed Dec 02, 2015 6:53 pm
Location: Tallahassee, FL

Re: 1988 635csi "Bring Her Back to Life"

Post by juiceof07 »

Ralph in Socal wrote:You'll need a set of e24 manual comfort seat rails to bolt the Recaros to. Easiest way to get them in the car without any modifications. They may bolt up to the electric rails you have on hand but they will be a manual/electric hybrid.

One 10mm head bolt at each corner of the seat underside for mounting. Please let the group know which way you make them work for future reference.


Ralph
Thanks Ralph. I was literally just trying to figure out how I'm going to get them in the car. The search for manual rails begin.
Luc

1998 540i/6 - Cosmos Black
1988 635csi - Working on Her... :|..Last 7 of Vin: 3266725
Post Reply