E28 528i vacuum lines

[Wazza o_O]

So, this is my first project and dip into anything mechanical. I pretty much have no clue.I am trying to figure out the routing for all the (I assume they are) vacuum lines.The origional ones were dry and cracked so I replaced what was there, the shop only had blue lines so please forgive that 
The only thing I'm confident on is that mostly they are wrong.

I've tried the search function but don't know what questions to ask.
I've tried the realoem but can't see how things link together

I seem to have slightly different hardware than I see in images, maybe because it's Australian? There is an additional valve on the drivers (right) side strut, with 3 nozzles, two connected to the underside of the intake manifold. The third had no hose attached. also I have 2 valves above the battery, where I've only seen examples with 1. if anyone can help or point me in the right direction that would be amazing
 


 


 


 
 

[Aldo525]

Hi, sure your issue is to have an australian version....Australia, Sweden and Switzerland had especial version related anti-polution systems...Could you send the last 7 digits of your VIN??....that way is more easy to find the right diagrams on all vacuum hoses.

[Wazza o_O]

Yeah it is Australian.

9386677

Thanks for the reply 

[Chicagotrader92]

Did you not replace one at a time to copy how it originally started? How's it running as it currently sits? 

[Aldo525]

Yeah it is Australian.

9386677

Thanks for the reply 

 

 

 

 

 

 

 

 

 

 

Well, this will be no easy to explain because there are no clear diagrams but I'll do my best:

There is two different vacuum "systems" in your engine not related one to another.

First "system" is the one that uses a the Purge Valve in the throttle body rubber boot: Note in your engine Purge Hose goes to under the windshield washer reservoir (canister location in e28, picture comes from an e23 car). FPR vacuum goes to under intake manifold. Cant see in your pictures the "check valve"....maybe is missing.



Second "system" is the tricky one. Follow the next diagram to connect the "Pressure Converter" (1) (thing over the right strut) with the (front) distributor vacuum regulator and the Electric Valve Red (red cap) (2). Dark Green (5) hose goes to under intake manifold. Light Green goes to Under Throttle Body (see next diagram) but seems to be necessary a "T" connector because the check valve (first "system") also goes to under throttle body.



Pressure Converter hoses location (colors)





And the following diagram is related to Distributor (rear) vacuum regulator, Throttle body upper and the another Electric Valve (black). This one I'm not sure if it is the same in your car (because the hoses is up and down) but may is just a drawing mistake.




Would be interesting to know more info/pictures maybe a number on this electric valve to validate the connection diagram above.




Hope all this be useful.

[Wazza o_O]

Did you not replace one at a time to copy how it originally started? How's it running as it currently sits? 

The majority were either disconnected or missing. I copied what I could but for most cases I took a guess as to which nozzles were correct, the car has been sitting idle for a few years.

It runs, but is quiet rough, have only started it once, to make sure it did start.
Its currently exhaustless and in a shed on stands. 
will be moving it out in the next few weeks

[Wazza o_O]

Yeah it is Australian.

9386677

Thanks for the reply 

 

 

 

 

 

Well, this will be no easy to explain because there are no clear diagrams but I'll do my best:

There is two different vacuum "systems" in your engine not related one to another.

First "system" is the one that uses a the Purge Valve in the throttle body rubber boot: Note in your engine Purge Hose goes to under the windshield washer reservoir (canister location in e28, picture comes from an e23 car). FPR vacuum goes to under intake manifold. Cant see in your pictures the "check valve"....maybe is missing.



Second "system" is the tricky one. Follow the next diagram to connect the "Pressure Converter" (1) (thing over the right strut) with the (front) distributor vacuum regulator and the Electric Valve Red (red cap) (2). Dark Green (5) hose goes to under intake manifold. Light Green goes to Under Throttle Body (see next diagram) but seems to be necessary a "T" connector because the check valve (first "system") also goes to under throttle body.



Pressure Converter hoses location (colors)





And the following diagram is related to Distributor (rear) vacuum regulator, Throttle body upper and the another Electric Valve (black). This one I'm not sure if it is the same in your car (because the hoses is up and down) but may is just a drawing mistake.




Would be interesting to know more info/pictures maybe a number on this electric valve to validate the connection diagram above.




Hope all this be useful.

 

 

Thanks Aldo
that is super helpful!
I will have a play over the weekendweek adjust according to your advice.

The valve in questions number is 7.20436 00 12V 5094
with a black cap.

 

The thing that I don't have, is that valve in the first diagram between the hoses 2 and 3 that you marked in blue

Cheers

[Aldo525]

So the another electric valve is indeed the "Black" one. Different model but the drawings should be ok.

That valve between blue hose 2 and 3 is the EGR valve used in this kind of anti polution device:.... maybe not covered in your model version.






And I think this should be the "EGR" installed in your version:




Or, over the years, any of those systems were eliminated.....
 

[Wazza o_O]

Thanks again.

Ihad a good crack at running the hoses. 

 

Just have 2 questions.
For the two lines which go under the throttle body, the Purge control vacuum hose and the pressure Converter hose (light Green in your diagrams), I've put a T joint and run them both to the front of the two nozzles.However I've found I have 2 nozzles under the throttle body. Another just behind this is capped off. Just want to check that i shouldn't use the 2nd one



And for the three lines going under the manifold,The breather vacuum hose, the FPR hose and the and the pressure regulator hose dark -dark Green in your diagrams.Can you confirm that the FPR hose goes to the  inner front nozzle (1) the pressure regulator to the rear inner nozzle (2).
Where does the breather vacuun hose go to? Is it the same place as the FPR hose, (with a t joint)or does one of these go to the rear nozzle on the outside of the manifold base (3) This is currently capped.

 

Thanks again

[Aldo525]

Thanks again.

Ihad a good crack at running the hoses. 

 

Just have 2 questions.
For the two lines which go under the throttle body, the Purge control vacuum hose and the pressure Converter hose (light Green in your diagrams), I've put a T joint and run them both to the front of the two nozzles.However I've found I have 2 nozzles under the throttle body. Another just behind this is capped off. Just want to check that i shouldn't use the 2nd one



And for the three lines going under the manifold,The breather vacuum hose, the FPR hose and the and the pressure regulator hose dark -dark Green in your diagrams.Can you confirm that the FPR hose goes to the  inner front nozzle (1) the pressure regulator to the rear inner nozzle (2).
Where does the breather vacuun hose go to? Is it the same place as the FPR hose, (with a t joint)or does one of these go to the rear nozzle on the outside of the manifold base (3) This is currently capped.

 

Thanks again

 

 

 

1) Checked at RealOem, Australian version have a different Throttle Body number (European and US versions had another part number) so the two nozzles should be for the two hoses, "T" connection is not necessary.....never seen before that configuration under the TB, good news.

2) Under Intake Manifold: I don't think the order of the hoses is important. In my case, I have them arranged like this: 1. Breather, 2. FPR and 3.... Here I have connected the hose that goes to the Cabin Temp sensor, located under the knee cover driver side (picture below RHD, your case). I would connect the Pressure Regulator hose here but check where the hose of the Cabin Temp Sensor is.

That sensor looks like this and that hose is connected under the Intake manifold pos 3. in my car. Maybe here would be uselful the "T" connector released joining Cabin Temp Sensor and Breather in one nozzle, leaving 1. FPR and 2. Pressure Converter alone.




 

[Wazza o_O]

 

 

 

1) Checked at RealOem, Australian version have a different Throttle Body number (European and US versions had another part number) so the two nozzles should be for the two hoses, "T" connection is not necessary.....never seen before that configuration under the TB, good news.

2) Under Intake Manifold: I don't think the order of the hoses is important. In my case, I have them arranged like this: 1. Breather, 2. FPR and 3.... Here I have connected the hose that goes to the Cabin Temp sensor, located under the knee cover driver side (picture below RHD, your case). I would connect the Pressure Regulator hose here but check where the hose of the Cabin Temp Sensor is.

That sensor looks like this and that hose is connected under the Intake manifold pos 3. in my car. Maybe here would be uselful the "T" connector released joining Cabin Temp Sensor and Breather in one nozzle, leaving 1. FPR and 2. Pressure Converter alone.




 

Thank you very much!
you've been so helpful. Definitely wouldn't have managed this without your assistance 

I will have a look for where the cabin temp sensor comes out and do it like you've suggested.

Cheers

[Aldo525]

Good luck with all the hoses and "rare" vacuum system, hope the engine run smooth and strong. None of those electric valves, purge, pressure regulator, etc are common in euro versions. Just consider that some of these devices maybe are not working as they should, so keep in mind to simplify all the hoses to the US or euro regular versions....a lot more simple compared to Australian version.

[Mike W.]

Just consider that some of these devices maybe are not working as they should, so keep in mind to simplify all the hoses to the US or euro regular versions....a lot more simple compared to Australian version.

I haven't chimed in yet but I've been following this. I agree with the above. As long as you don't have emissions testing. Now I'm greener than most so I don't automatically discount emissions controls, but it can be madness trying to figure out and make this stuff work as old as it is, and if something doesn't work parts may not even be available.

This is mostly reminiscent of US spec E12 530i's, the EGR system, but we got all that with an air pump too. But with a dash of US spec E12 528i (catalyst cars) thrown in and a bit of US spec E28 535i, also catalyst.

Assuming you do not have emissions testing here is what I'd do.

Run manifold vacuum to the FPR.
Run manifold vacuum to the green device on the thermostat housing, then from that to the purge valve on the intake boot.
Run vacuum lines from the distributor to the throttle body, direct without any additional control. The line closest to the dist body (at least on US cars) is the retard side. When it's connected right the idle speed will drop significantly. When the vacuum port on the outer side of the distributor is connected correctly you won't notice anything at idle. It's above idle when the throttle is opened that it comes into play.
Run manifold vacuum to the cabin temp sensor. It's supposed to have a restrictor in there to limit what is in essence a vacuum leak, but I didn't on my US 535i and never had a problem.

I would not hook anything up to the pressure converter or the vacuum switching valves, I'd ignore them and ignore the EGR valve.

You do all that you will keep vacuum control on the distributor, both advance and retard, and retard on this isn't bad, it only happens at idle. (explaining how this works is complicated, I can if you want, but it's complicated and long)
The fuel pressure should be correct as it's referenced to manifold air pressure, and like every other BMW I've owned with FI pre 1990, which is a bunch.
You will retain the gas vapor purge system, which doesn't hurt anything but does help a bit on minimizing smog.
You will retain airflow thru the cabin temp sensor so heat/A-C works as designed.

[Federico]

I think I found the correct schematic for that EGR system (I agree with ripping it out if possible)