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How To Fit E90 Brake Booster Into BMW E30 M52 Swap RHD | Slim E9X Servo Install Guide | 043
In this video, I share a detailed guide on how to install a BMW E90 brake booster into a BMW E30 right hand drive.
Here's what I used in this video:
E90 Brake Servo: ebay.us/TopN1v
1602/2002 Brake Fluid Reservoir: ebay.us/44sum7
Grommets: ebay.us/2GdX3P
Brake Line Adapters M12 to M10: ebay.us/q0Q2kD
13mm Vacuum Bung: ebay.us/65SM1E
Brake Line T-piece: ebay.us/gEJ3pw
Longer Clevis Pin M10 35mm: ebay.us/bDqOG5
The Wrong Brake Line Flaring Kit: ebay.us/x3P5yu
My reason for wanting to E90 servo swap my BMW E30 build is quite simple. I'm planning to do an M52 engine conversion on this car, and the E30 brake booster will not simply work thanks to being too wide of a diameter and fouling both an M52 or M50 intake manifold.
There are a few common ways to solve this problem, the seemingly most simple would be to relocate the E30 original brake servo slightly over to one side, away from the manifold, this works but it involves cutting the firewall and drilling new holes, plus modifying the clevis in a way which requires you to buy an extra one.
In the UK, a very common route is to use a Renault Clio Servo, this is a very specific brake booster found on a Mk2, 1.2L Clio from 2001-2005 model. These are becoming near impossible to source now, let alone in good condition. I couldn't even find a good photo of one. But this comes with its own difficulties regarding the clevis again as it has an adjustable push rod.
In the US, the equivalent to this would be the Porsche 944 brake booster swap, but these are less common in the UK, and they are very old parts now which is off-putting.
X3 brake servos are also becoming a common swap, but whatever option you go with will come with its own set of compromises and complications. I settled on the E90 E92 E9X brake servo to fit into my E30 as the best option, although still not as simple as I'd like.
When fitting a BMW E90 brake booster into an E30, there are plenty of factors to be aware of. If you live in a LHD area, like the US, you will find that LHD E90s have the brake master cylinder ports on the booster on the wrong side for the E30, so a top tip for those across the pond is to pick up a RHD E90 brake servo.
On that note, if your E30 is left hand drive, you will need to modify the clevis, many do this by simply welding the E30 clevis onto the E90's rod. However, for a RHD install, I found myself to be very lucky and no welding was required - you can stick with the E90's original fork which was a massive plus thanks to the janky brake pedal linkage.
For LHD E30's the clevis meets the brake pedal directly so there is insufficient space for the larger E90 fork.
Despite the E90 being a slimmer brake booster to fit with M50 manifold, the brake fluid reservoir is still too large. Luckily you can pick up a BMW 2002 or a 1602 brake fluid reservoir. There are a couple of versions, one with a clutch line takeoff and one without. With a RHD E30, you can get the latter.
To fit the 2002 brake fluid bottle you need to switch the rubber grommets out on the master cylinder for smaller ones.
Once this is done, you will need to fit M12 to M10 brake line adapters so your BMW E30 brake lines will work with the new E90 master cylinder ports.
You'll also need to bung the spare hole for vacuum on the E90 booster and switch the E30's vacuum line into the other.
I also had to trim the E30 engine bay sound deadening so the E90 booster would mount flush to the firewall on its two studs.
With it mounted in place, I set about bending my brake lines to meet the new brake master cylinder, the front E30 brake lines needed to go via a T-piece splitter to feed both front calipers as my E30 is a non-ABS model.
I even give a guide on how to do bubble flare brake line fittings using a double flare brake line kit, it works pretty well considering its not a bubble flare tool.
Finally, I used a longer clevis pin with some stacked washers to connect the E90 booster fork to the E30's brake linkage.
For more helpful how-to guides and restorations: www.spannerras...
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