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08+ BMW 1 Series (E82) Brake Lines (OEM Caliper) INSTALLATION GUIDE

Tools Needed:

11mm Wrench, 14mm Wrench, 17mm Wrench

11mm Flare Wrench (short flare wrench required for Standard & Full Kits)

A friend or pressure bleeder (recommended)

Parts Needed:

None (Full Kit), 1 Liter Brake Fluid (Basic & Standard Kit)

Install Time: 30-45 minutes (Basic Kit), 1 to 1.5 hours (Full Kit)

Difficulty (1 Easy, 5 Hard): 1 (Basic Kit), 2 (Full Kit)

CAUTION!!! BRAKE FLUID IS CORROSIVE AND WILL DESTROY PAINT!!!  BE CAREFUL AND DO NOT GET BRAKE FLUID ON ANY PAINTED SURFACE.  IF YOU DO, QUICKLY WIPE OFF BRAKE FLUID WITH SOAPY WATER.

Removal

  1. Raise car – We recommend you put the car on a lift.  This can be done on the floor with a jack and jack stands however it will be difficult.
  2. Take off all the wheels - OEM lug bolts are 17mm.

FRONT BRAKES:

  1. Free the OEM rubber brake lines from its bracket – The OEM brake line is held in place by a bracket on the shock assembly.  The line is held to this bracket via rubber grommets.  Push the rubber grommets out of the brake line bracket.  BE CAREFUL WHEN PUSHING THE RUBBER GROMMETS OUT OF THE BRACKET.  THE BRACKET IS THIN AND CAN BE BENT OUT OF SHAPE.  SUPPORT THE BRACKET WITH ONE HAND WHILE PUSHING THE RUBBER GROMMET OUT.
  2. Unbolt the OEM rubber brake line from the OEM metal brake line – Follow the OEM rubber brake line from the brake caliper until you reach the OEM metal brake line.  There is a compression fitting connecting both lines.  Put a container underneath this fitting to catch the brake fluid.  Unbolt this fitting by first holding the bottom fitting (rubber line side) with a 17mm wrench.  Hold the bottom fitting in place and do not let it spin.  Then unscrew the top fitting (metal line side) with an 11mm flare wrench.  DO NOT ATTEMPT TO UNBOLT THE 11mm COMPRESSION FITTING WITHOUT A FLARE NUT WRENCH AS DOING SO MAY STRIP THE FITTING.
  3. Unscrew the OEM rubber brake line from the brake caliper – Use a 14mm wrench and unscrew the OEM rubber brake line from the brake caliper.
  4. Go to STEP 1 in Installation.
  5. Repeat on the other side.

REAR BRAKES:

  1. Unbolt the outer OEM rubber brake line from the OEM metal brake line – Follow the OEM rubber brake line from the brake caliper until you reach the OEM metal brake line.  There is a compression fitting connecting both lines.  Put a container underneath this fitting to catch the brake fluid.  Unbolt this fitting by first holding the bottom fitting (rubber line side) with a 17mm wrench.  Hold the bottom fitting in place and do not let it spin.  Then unscrew the top fitting (metal line side) with an 11mm flare wrench.  DO NOT ATTEMPT TO UNBOLT THE 11mm COMPRESSION FITTING WITHOUT A FLARE NUT WRENCH AS DOING SO MAY STRIP THE FITTING.
  2. Unscrew the OEM rubber brake line from the brake caliper – Use a 14mm wrench and unscrew the OEM rubber brake line from the brake caliper.
  3. Go to STEP 3 in Installation.
  4. Repeat on the other side.
  5. Unbolt the inner OEM rubber Brake line from the OEM metal brake lines (Excludes Basic Kit) – The inner brake line is located near the middle of the car, below the suspension subframe.  Follow the brake line from the rear brake caliper until the OEM metal brake line ends and is replaced by the OEM rubber line.  Put a container underneath the lower compression fitting to catch the brake fluid.  Unbolt the lower fitting assembly by first holding the top fitting (rubber line side) with a 17mm wrench.  Hold the top fitting in place and do not let it spin.  Then unscrew the lower fitting (metal line side) with an 11mm flare wrench.  DO NOT ATTEMPT TO UNBOLT THE 11mm COMPRESSION FITTING WITHOUT A FLARE NUT WRENCH AS DOING SO MAY STRIP THE FITTING.  The top fitting assembly is attached to a bracket on the chassis above the rear suspension subframe.  This is difficult to reach.  Unbolt this fitting by first holding the bottom fitting (rubber line side) with a 17mm wrench.  Hold the bottom fitting in place and do not let it spin.  Then unscrew the top fitting (metal line side) with an 11mm SHORT flare wrench.  DO NOT ATTEMPT TO UNBOLT THE 11mm COMPRESSION FITTING WITHOUT A FLARE NUT WRENCH AS DOING SO MAY STRIP THE FITTING.
  6. Go to STEP 4 in Installation.
  7. Repeat on the other side.

Installation

FRONT BRAKES: 

  1. Install the front brake lines – The new front brake line is the longest line in the kit and has the rubber grommets on it.  Install the new brake lines (male fitting side) to the brake caliper using a 14mm wrench.  DO NOT OVERTIGHTEN.  Screw the other side (female fitting side) of new brake line to the OEM metal brake line.  Hold the bottom of the compression fitting with a 14mm wrench (do not let the fitting spin) and tighten the top compression fitting with an 11mm flare nut wrench.  DO NOT OVERTIGHTEN.
  2. Secure the new brake line to the brake line bracket – There are rubber grommets on the new brake line.  Push the rubber grommets into the brake bracket.  BE CAREFUL WHEN PUSHING THE RUBBER GROMMETS INTO THE BRACKET.  THE BRACKET IS THIN AND CAN BE BENT OUT OF SHAPE.  SUPPORT THE BRACKET WITH ONE HAND WHILE PUSHING THE RUBBER GROMMET IN.

REAR BRAKES:

  1. Install the rear outer brake line – The new rear outer brake line is the medium length line in the kit and has a long male fitting on one side and a female fitting on the other.  Install the new brake line (male fitting side) to the brake caliper using a 14mm wrench.  DO NOT OVERTIGHTENScrew the other side (female fitting side) of the new brake line to the OEM metal brake line.  Hold the bottom of the compression fitting with a 14mm wrench (do not let the fitting spin) and tighten the top compression fitting with an 11mm flare nut wrench.  DO NOT OVERTIGHTEN.
  2. Install the rear inner brake line (Excluding Basic Kit) – The rear inner brake line is the shortest length line in the kit and has a female fitting on both sides.  Either side can be used on either side of the OEM metal brake line so orientation does not matter.  Install the new brake line to the top OEM metal brake line first.  Hold the bottom of the compression fitting with a 14mm wrench (do not let the fitting spin) and tighten the top compression fitting with an 11mm flare nut wrench.  DO NOT OVERTIGHTENAttach to other side to the bottom OEM metal brake line.  Hold the bottom of the compression fitting with a 14mm wrench (do not let the fitting spin) and tighten the top compression fitting with an 11mm flare nut wrench.  DO NOT OVERTIGHTEN. 

With the new brakes lines install, it’s time to bleed the brakes.  There are 2 ways to bleed the brakes on the BMW 135i.  The factory specifies that the brakes be pressure bleed.  However, regular gravity bleed (with a friend) works as well.  Since most people have friends than pressure bleeders, we will explain the gravity bleed process.

BLEEDING BRAKES (Gravity Bleed):

  1. Fill the master brake cylinder with brake fluid – Ensure that master brake cylinder does not empty.  If it does, you will have to start the bleeding process over again from the beginning.
  2. The brakes need to be bleed in the correct pattern.  BMW specifies that the brakes be bleed in this order: Rear Right, Rear Left, Front Right, Front Left.
  3. Attach the clear vacuum line included in the brake line kit to the bleeder screw on the brake caliper.  The bleeder screw looks like a nipple with a hole in the middle.
  4. Push the brake pedal hard 5 times to build pressure and hold the brake pedal down on the last pump.
  5. Open the bleeder screw on the caliper – Use an 11mm wrench.  Watch the fluid in the vacuum line for air bubbles.  Close bleeder screw.
  6. Check all brake line connections – Make sure all connections are dry and that there is no leaks.  Wipe off any brake fluid.
  7. Repeat Steps 8 & 9 until all air bubbles are gone and all old fluid has been replaced with new fluid – Old brake fluid is dark in color.  Bleed until the brake fluid changes to a lighter color.
  8. Repeat Steps 7 to 10 on all brake calipers following the pattern discussed in STEP 6.

Go through the car and make sure there is no brake fluid on the brake line connections.  Wipe off any brake fluid you see with soapy water.  Ensure that there is no brake fluid on the brake caliper as brake fluid will eat the paint finish on the brake caliper.

Test the brakes.  If the brakes feel “spongy” or if there is no pressure in the brake pedal, there is air still trapped in the brake lines or there is a leak at a connection causing air to be pulled into the system.  Go through all the connections and check each fitting to make sure they are COMPLETELY tight.  Repeat the brake bleeding.

Put the wheels on the car and put the car on the ground.  Move the car at 5 mph and ensure that the brake system is operating correctly.  Installation is now complete. 

ENJOY!

If there are any problems or questions about installation, please contact us at contact@evolutionracewerks.com or (626) 814-3403.