Spent a few hours getting all those wires that were loose wrapped up and cleaned up so the battery area wouldn’t look so sloppy. Best case scenario would be to yank it all out, paint it and rewire everything from scratch but that’s not happening anytime soon. So I pulled some wire. Wrapped some up. Tied some down and hooked it all back up. While it was apart I made sure all the ground wires were securely grounded, a weakness of the 2002. Then I re grounded the electric fan and buttoned it all up and tested everything. All in all a pretty satisfying day. Gonna make this one short so I can enjoy the 2nd to last episode of Breaking Bad.
Now that I know my brake booster is bad I need to decide on what to do, replace it or repair it. New brake boosters are no longer available. Rebuilding them is about $200. The 2002 Tii brake booster is longer and more narrow. It was needed to fit the larger fuel injected intake manifold. Since I am going to upgrade to dual side draft carbs the extra space will allow me to run a much wider variety of air cleaners. Since these are no longer made and Tii’s are more rare, there is usually a premium on the Tii brake booster. I started looking for Tii boosters and didnt find much. I put a wanted ad on BMW2002faq.com and I got an email from my buddy Julio at Euro Vintage Parts. He had a really nice one in great condition for about the price of a rebuild! He is in Northern California and amazingly enough I happened to be up there and was able to swing by and pick it up! The down side is that the Optima red top battery I bought recently is too big so I will either have to relocate the battery to the trunk…which was on my short list of things to do, or get a smaller battery for the stock location. The Brake Booster was in great shape with just a bit of surface rust. I sanded it down and hit it with a little satin black Rustoleum. (Said in Edd Chyna’s british accent for you Wheeler Dealer fans!) Once cleaned up, Ken Blasko at Vintage BMW Racing did the install. In some cases new brake lines need to be installed because of the booster being longer. Ken and Tom were able to creatively stretch my brake lines.
WOW. I picked the car up and drove down the street, pressed the brakes for the first time and I almost flew into the windshield…the brakes were absolutely amazing! I know the Tii Brake Booster is supposed to add ZERO performance over the standard unit, but lets just say fresh brake fluid, rear brake adjustment, bleeding and a properly working booster all make a HUGE difference. My old booster may have been failing for months. Now my idle is nice and smooth even stopped with my foot on the brake and it stops on a dime! So here are a few pics. Now I need to clean up those wires on that side of the engine bay…Looks like thats my next job!
BMW 2002 Tii Brake Booster
Good condition, just a little surface rust.
Paint of choice! Quick drying Black Satin
Sanded and a bit of paint.
Dried and ready for install
Installed! Tight fit with a small battery there. Red Top Optima would not fit!
Tights fit…just a wee bit of room. Either a smaller battery will need to go in or the battery will have to be moved to the trunk.
The car was running great except I have a rough idle when stopped. It was very frustrating as when I’m driving the car is fast, peppy and fun to drive. When stopped it sputtered and the idle got very lumpy. I checked for leaks in the intake and did research and found that these are the symptoms for a failing brake booster. More to come…..
For 2 years or so I have been enduring this exhaust smell in my car. I tried to adjust the trunk latch so it would seal better. I was at the most extreme setting and still I was seeing light get into the trunk. It was not a small gap. So I decided for a cheap temporary fix just to see exactly what the problem is. I got a $3 roll or rubber weatherstripping and applied to to the trunk lid. Closed the trunk and drove. It’s been about a week and ZERO exhaust smell In the car! I can’t believe that I let this go in for so long and never fixed the issue! Well here is a pic of the stuff I used.
Today was a day that has even 3 years in the making! Today I installed the carpet kit I bought from Esty. It you are unfamiliar with Esty, let me tell you a but about her. She has many 02s and has designed carpet kits that are precut at a reasonable cost. Here is her website.
Years ago I bought a dark blue carpet kit to replace my now 36 year old dark blue carpet. My carpet now if white in places due to sun bleaching and old age. The kit was excellent. High quality Very well made and in the middle I got stuck and she emailed me back within minutes with more info. That’s amazing. Any issues with the kit is strictly the fault of the installer (Me). So after 7 hours of work and a few emails from Esty…I am VERY pleased with the outcome! No more dirty and dingy carpet….Definitely makes the interior much nicer…now the next major upgrade for the interior is the dingy headliner.
Before – 37 year old Carpet
Old Carpet out
Additional Sound and Insulation Applied
Part 1 of the trip was a dream. About 8pm I set off from Sacramento and headed south on interstate 5. Keeping the car under 80 the whole way was the plan. When I stopped for gas I topped off the oil level. Gotta make sure the engine stays nice and lubricated! I am getting exhaust smell in the car. That’s not new. I think I need to replace my trunk seal as well as fill the holes left from the euro bumper conversion. Again the car run flawlessly until the very end of the trip. I got off the freeway and heard a strange noise. Uh oh. What’s that! It was a high pitched loud whine. It sounded like a poor stereo install with a loud alternator whine. I turned the radio and the noise was still there. I looked at all the gauges and all was well. The performance was the same. Just a loud whine from the engine. I was close to home and now it was 24 hours since I had slept and I was exhausted. I nursed it home. Parked it. Sent Ken Blasko an email and went to sleep. It was 5am. Around 8 I get a text message from Ken saying he would be by about 830 am! Wow! Ken gets there and we looked at the oil pressure. Checked it with a gauge. Pulled the plugs and checked them but we couldn’t find the source of the whine or anything wrong. He put a rag near the carb and the noise got muffled. Hmmm. He spruced carb cleaner all over the carb while it was running and got nothing. So this was odd. He moved some thins around and found that the main throttle shaft was letting in air which was making the loud whine. Everything else looks pretty good.
So to wrap it up the Break in trip was a huge success. It’s shaking out the little things that may or may not be related to the engine work.
Doing a drive from Newport Beach to Sacramento to visit family. It’s about 450 miles each way. If you are not familiar with the drive its all flat and straight interstate highway except for the Grapevine which is a steep and windy grade of road that is probably alot like the Autobahn. This is part 1. The drive up north.
The car ran absolutely perfect! The power at highway speeds is considerably more than before. It now pulls hard at 80 and keeps going! I didn’t go too far yet as I still wanna keep it below redline for a bit. Before te engine work the car would go up the steep highway at 85 mph but would kinda max out there. Other cars are usually huffing and puffing doing 65 and all the trucks are doing about 35. So 75-85 is actually good. Now after the work the car pulls pas 80 and is still going when I pull off. Wow. I would bet triple digit speeds are easily possible up this steep grade and under load. Impressive. It ran at 80 so perfectly and when I needed the power it was readily available. Very very happy with how it’s running. Temps are perfect. No issues and the oil pressure light used to flicker after freeway runs. Nope not a peep. I really have not found a downside for the 292 cam yet! I really love how this car is running!!
Just picked up the car from Ken at Vintage BMW Racing and I am more than pleased! The car has been freshened up and is a BEAST! The power comes on almost from idle. (I thought a 292 cam wasn’t supposed to have alot of torque down low?) Then as the revs build it starts to come to life. As it approaches redline it’s screaming. How can I accurately describe the engine? Free revving. It just revs and quickly. Compared to before it feels like a lightweight flywheel is in the car. It just revs and fast! To me, THIS is how a 2002 should run.
I have to thank Ken Blasko at Vintage BMW Racing. He made this a breeze. He was very flexible when it came to his schedule. He did the work in a quick fashion. He told me he only does one job at a time so he focuses all his attention on one project. I can tell my car got his FULL attention. His shop is great. I was in awe at the shells waiting to be built, the engines on stands that were waiting to be dropped into customers cars or his race car, and the spare parts on the walls neatly marked and cataloged. This came in handy when my head came back with bad news from the machine shop. He had a head that was clean, had a valve job and just needed to be assembled. He then checked the piston clearance to make sure I had plenty of room to run the 292 cam. He went through the car, and fixed alot of little things that just make the car more reliable. Motor mount, transmission mount, axle bolts, alternator bracket, etc. He then found the carb was missing some parts and there were some parts stuck in the carb keeping the throat open. He dealt with that as well as pointing out a bent diff mount that I will address when I upgrade my diff to a 3.91 LSD. This was all in addition to fixing the oil leak from the front cover which was why the car was there in the first place. Oh and he sent LOTS of pics showing the progress of the car. What I also loved is that since he owns 2002s and races 2002s and builds 2002s, he KNOWS 2002s and how they should feel. How they should run. What to expect from certain upgrades and modifications. Then he gives great advice on what to do. Now that this engine spins up so freely, I look forward to the 5 speed and 3.91 LSD. Those will add more quickness to the car as well. Stay tuned for more upgrades to come!
The car is getting close! The bottom end and front cover are put back together. The head is back on the block and it’s getting close to being fired up! If all works out well maybe I can get the car back this weekend.
So the new head is complete! New valves, guides, rockers, springs, and 292 cam! Here are the pics.