How to restore E30 - 3 Series BMWs built between 1982 &1994. Covers all models from the 316 to the M3. Advice given on acquiring a good E30 plus restoring and modifying engines, bodywork, trim, electrics, suspension and much more Covers all E30s from early 316s to the M3 Frank, detailed and practical buying advice Bodywork and trim refurbishing techniques Repairing electrics and mechanical parts Advice on tuning & building modified engines Comprehensive list of yearly updates & specs Detailed information on Alpina and M3 cars By Andrew Everett BMW E30 - 3 Series Restoration Bible Published by Brooklands Books BROOKLANDS BOOKS LTD. P.O. BOX 146, COBHAM, SURREY, KT11 1LG. UK [email protected] ISBN 9781855209428 BMW30E © 2011 Andrew Everett and Brooklands Books Limited All rights reserved. No part of this book may be reproduced, stored, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without permission in writing from the publisher and author. Whilst every care has been taken in the preparation of this book, neither the author nor the publisher can accept any liability for loss, damage or injury caused by errors in, or omissions from, the information given. ACKNOWLEDGMENTS Writing a book like this is the most long winded thing I’ve ever done, and has taken a year of my life. Originally it was planned as a restoration guide but it sprouted from there and has covered a great deal more; it is at its best when com- bined with a Bentley Publishing workshop manual (see details on page 170 and 175), probably the best manual on the market anywhere. Inspiration has come from many places but the guy who spent days taking digital pictures and really started the ball rolling is my good pal Alf Dickhaut from Germany, an M Power specialist who also distributes stainless steel brake hoses. When he should really have been with his better (and prettier) half Sandra, he spent time in a cold workshop taking many of these photos - about 130 in all. Thanks Alf. Next up comes Paul Wager from Total BMW Magazine who took the rust pictures of a particularly nasty 325i amongst others - thanks to him and the magazine for all their help. Brendan Purcell from the BMW Car Club’s Irish section donated lots of 318iS knowledge including the sections of timing chain replacement which saved me a lot of grief. He also wrote the foreword which sums up the E30 nicely. Next we have almost the entire crew from www.e30zone.co.uk for various pearls of wisdom and yet more inspi- ration - Ian Haynes, Ant Woodjetts, Adam Patchton and just about everyone else there I think. Peter Walsh from PMW in West London gave hours of time with questions about E30’s and the M3 in particular. Neil Waterhouse of All Gears in Worksop allowed me a week of workshop space and the use of facilities to build a 2.8 litre engine. Julian Smith helped with this engine (and the section on 2.7 builds) by telling me about shortening the pistons, thus saving me grief later. Then we have BMW (GB) who allowed us to use so many technical drawings and illustrations plus access to the elec- tronic parts catalogue (E PC or ETK) to answer many of the questions. Thanks also to Bridgegate BMW, my local BMW main dealer in Chesterfield. In particular the guys in the parts department who answered many annoying questions - thanks to all the guys there for all the hassle, Dean, Rob, John, Adrian and Mike in particular. Because these guys were there in the eighties when the E30 was a new car, they remember an awful lot and old habits die hard! Last but certain- ly not least is the Brooklands Books team who of course made all this possible by agreeing to publish what seemed an unknown quantity - I think the term ‘leap of faith’ sums it up. Many hours (days!) was spent poring over the manuscript and they really are a pleasure to work with. Other helpers include Phil Crouch for technical advice and of course pho- tographer Craig Pusey who donated some of his excellent photographs from various Total BMW and BMW Car maga- zine shoots. Thanks also to photographer Matt Harvey, plus Richard Dobney at BMW GB for the loan of his photos taken at the E30 press launch in 1983. Thankyou all. Andrew Everett Foreword It is amazing to think that time has passed by and that the second BMW “3 Series” has achieved such status that it war- rants this special book on its 21st anniversary. Maybe it is due to the sheer longevity of its design, its ability to satisfy the keen driver or its iconic status - but, whatever it is, there is no doubt that the E30 is one car from the past that will stay with us into the future. It is a pending classic and prices for well kept models have started to escalate; furthermore, there is a core of well cared for cars out there requiring basic attention by their dedicated owners. As a result, there has never been a better time for a book of this sort. By focusing on the common faults which crop up repeatedly and by giving detailed, simple instructions regarding repairs, this book will be uniquely invaluable for own- ers who wish to try their hand at their own maintenance, especially those who may previously have been prevented from doing so by a lack of technical know-how or specific knowledge. When Andrew invited me to provide an input to the preparation of this book, I immediately agreed as I am all too aware of the many people who are looking for simple advice to fault find and repair their cars through my involvement in forums, my own website and BMW clubs. I feel this book is an excellent reference for those people who are deeply pas- sionate about these cars, now three generations old. Being a fellow E30 owner, I am well aware of the devotion they continue to instill in the face of modern machinery. All of the models have the essence of character, put the driver first, have great depth to their performance, are well styled, classy, are robust, surprisingly cheap to run and quite easy to work on. They have all the qualities I like in a car; so much so, I do not envisage a day that I will be without my own car. I’ll end with this note: when you are out driving next, look around for cars from the ’80s. The E30 is one of the very few models of that decade which can be seen every day on our roads - and there is no better statement than that. Brendan Purcell The Press Launch Team March 1983 CONTENTS Acknowledgments Introduction to the E30 7 Chapter 1 E30 - The Models 11 Chapter 2 Buying an E30 29 Chapter 3 Keeping Your E30 Alive! 41 Chapter 4 Body Restoration 47 Chapter 5 Suspension and Steering 59 Chapter 6 Brakes 65 Chapter 7 Transmission 69 Chapter 8 Engine Types 77 Chapter 9 Cooling and Heating 97 Chapter 10 Fuel System 105 Chapter 11 Electrical System 115 Chapter 12 Interior Restoration 123 Chapter 13 Restoring Other Parts 127 Chapter 14 Modifying the E30 129 Chapter 15 The E30 in South Africa 159 Chapter 16 E30 Standard Specs 161 Useful Names and Addresses 170 Index 171 ROAD TEST SERIES RACING & THE LAND SPEED RECORD Abarth Road Test Portfolio 1950-1971 The Land Speed Record 1898-1919 AC Cars 1904-2009 The Land Speed Record 1920-1929 AC & Cobra 1962-2011 The Land Speed Record 1930-1939 Alfa Romeo Giulietta Gold Portfolio 1954-1965 The Land Speed Record 1940-1962 Alfa Romeo Giulia Berlina Lim. Edit. Extra 1962-76 The Land Speed Record 1963-1999 Alfa Romeo Giulia Coupes Lim. Edit. Ultra 1973-76 Can-Am Racing 1966-1969 Alfa Romeo Alfasud 1972-1984 Can-Am Racing 1970-1974 Ford Fairlane Performance Portfolio 1955-1970 Morgan Three-Wheelers Ultimate Portfolio 1909-52 Alfa Romeo Spider Ultimate Portfolio 1966-1994 Ford Ranchero Muscle Portfolio 1957-1979 Morgan Four-Wheelers Ultimate Portfolio 1936-67 Can-Am Racing Cars 1966-1974 Alfa Romeo Spider & GTV Perf. Port. 1995-2005 Ford Galaxie & LTD Gold Portfolio 1960-1976 Morgan Ultimate Portfolio 1968-1990 The Carrera Panamericana Mexico - 1950-1954 Allard Limited Edition Ultra Falcon Performance Portfolio 1960-1970 Morgan Ultimate Portfolio 1991-2009 Le Mans - The Bentley & Alfa Years - 1923-1939 Alpine Renault Ultimate Portfolio 1958-1995 Ford GT40 & GT Ultimate Portfolio 1964-2006 Morris Minor MM & Series II Road Test Portfolio Le Mans - The Jaguar Years - 1949-1957 Alvis Gold Portfolio 1919-1967 Ford Torino Performance Portfolio 1968-1974 Morris Minor 1000 Road Test Portfolio Le Mans - The Ferrari Years - 1958-1965 AMC Rambler Limited Edition Extra 1956-1969 Ford Bronco 4x4 Performance Portfolio 1966-1977 Nash Limited Edition Extra 1949-1957 Le Mans - The Ford & Matra Years - 1966-1974 AMX & Javelin Gold Portfolio 1968-1974 Ford Bronco 1978-1988 Nash-Austin Metropolitan Gold Portfolio 1954-1962 Le Mans - The Porsche Years - 1975-1982 Armstrong Siddeley Gold Portfolio 1945-1960 Shelby Mustang Ultimate Portfolio 1965-1970 Nissan Skyline GT-R Ultimate Portfolio 1969-2010 Le Mans - The Porsche & Jaguar Years - 1983-91 Aston Martin Gold Portfolio 1921-1947 Mustang Muscle Portfolio 1967-1973 Noble Sports Cars Road Test Portfolio Le Mans - The Porsche & Peugeot Years - 1992-99 Aston Martin Ultimate Portfolio 1948-1968 High Performance Mustang IIs 1974-1978 NSU Ro80 Limited Edition Mille Miglia - The Alfa & Ferrari Years - 1927-1951 Aston Martin Ultimate Portfolio 1968-1980 Mustang 5.0L Muscle Portfolio 1982-1993 Oldsmobile 1948-1963 Limited Edition Premier Mille Miglia - The Ferrari & Mercedes Years - 1952-57 Aston Martin Ultimate Portfolio 1981-1993 Ginetta Cars Limited Edition Ultra 1958-2007 Oldsmobile Muscle Portfolio 1964-1971 Aston Martin Ultimate Portfolio 1994-2006 Targa Florio - The Porsche & Ferrari Years - 1955-1964 Goggomobil Limited Edition Cutlass & 4-4-2 Muscle Portfolio 1964-1974 Auburn Cord Duesenberg - A Brooklands Portfolio Targa Florio - The Porsche Years - 1965-1973 Hispano-Suiza Road Test Portfolio Opel GT Ultimate Portfolio 1968-1973 Audi Quattro Gold Portfolio 1980-1991 Honda - Acura NSX Ultimate Portfolio 1989-2005 Opel Manta Limited Edition 1970-1975 Audi TT Performance Portfolio 1998-2006 Honda CRX 1983-1987 RESTORATION & GUIDE SERIES Packard Automobiles 1920-1958 - A Portfolio BMW 2002 - A Comprehensive Guide Austin Seven & Ten Road Test Portfolio Honda S2000 Performance Portfolio 1999-2008 Pantera Ultimate Portfolio 1970-1995 Austin-Healey 100 & 100/6 Gold Port.