BMW E9 - ASSEMBLY ORDER
This is not a finished text and is subject to adjustments and improvements.
It is intended as a general guideline to avoid getting lost in teh proces.
Some things can also be done in a different order and depend on your project and situation.
Advice is always welcome! E9 forum
PHASE 1 - the subframes, hard lines and wiring
running all the hard lines (hydraulics, fuel, etc) before something big like an engine is in the way, but after the subframes/suspension/brakes are in. If you are making these lines, everything you need to connect to must already be in (brakes, master cylinder, etc.), which could change the order for you, and you may want to remove the brake booster after again, before installing the engine.
SUBFRAMES
rear suspension
rearbrakes
master cilinder
front suspension
https://e9coupe.com/forum/threads/front-strut-assembly.32908/#post-270793
front brakes
brake booster
HARD LINES
brake lines
fuel lines
FIREWALL INSULATION
WIRING
Running the wiring after insulation, but before most anything else on the interior.
Hook up as much of the fuse block wires as possible (and check them) before sliding it into position. If you want the bulk of wires to go through the mounting bracket, you can actually slide the full wired block through at just the right angle. changing wires once they are through that bracket is difficult.
Deal with sunroof drains while the interior is empty as possible, before headliner.
PHASE 2 - the engine
HOSES
Pre install some of the hoses that go into the firewall since they are a bit hard to get to once the engine is in (not sure about this).
THE ENGINE
engine
transmission
drive axle
ignition
https://e9coupe.com/forum/threads/123ignition-distributor-install.16396/
expansion tanks
power steering tank
radiator and hoses
carburettors
exhaust system
PHASE 3 - the interior
It seems best to do the interior after you're pretty certain everything mechanical and electrical works.
Get carpet, upper pillars and headliner in pretty early after wiring. Once the headliner is in, get the interior aluminum trim in place to hold the edge well
Order of the front interior is absolutely critical (carpet, pillar trim, HVAC, dash parts, console. Many of these will only be accessible sequentially. To me, this was the single most important order, and one where we do need a comprehensive step by step. I almost posted one a few weeks ago, probably worth doing one in the DIY section.
Leave all exterior trim, grills, lights, rubber till very late just in case you need to fix any paint after all that assmbly.
Front/rear windows, hood and doors come near the end. As mentioned, trunk is sort of independent (inside and lid), do it whenever you want.
INSULATION
TRIM & HEADLINER
pillar trim
headliner
Headliner folds over on itself at the pillars and then goes over the vinyl covered pillars.
Also the vinyl on the back pillars has to go on before the glass because the rear gasket actually goes over a portion of the pillar vinyl to help hold it in place.
DASH & HEATER
https://e9coupe.com/forum/threads/re-installing-the-dashboard.41186/
https://e9coupe.com/forum/threads/i-need-help-removing-my-dashboard.22219/#post-162463
heater
AC
shifter console
dash tray
demister vents
lower dash pad
dash and instruments
upper dash pad and instrument cowl (final positioning of demisters?)
package tray
rear seat belts
shift console sides
dash under cover
glove box
fuse box hatch
rear arm rests/side cards
door cards
carpets
PEDALS & STEERING
pedal box
pedals
steering column
PHASE 4 - the doors and windows
https://e9coupe.com/forum/threads/rubber-faq.35487/
door edge trims and piping (riveted on)
door latches and locks
side mirror(s) mounting
side belt line trim (at least doors and rear quarters)
door windows
rear side windows
front and rear windows
https://e9coupe.com/forum/threads/windshield-installation.46436/#post-409522
https://e9coupe.com/forum/threads/tips-on-windshield-replacement.18107/#post-127700
glass trims (exterior)
door sill trims
doors
https://e9coupe.com/forum/threads/re-installing-rubber-weatherstripping-around-the-door.43816/
https://e9coupe.com/forum/threads/rubbers-51216740180-181.28290/
hood
https://e9coupe.com/forum/threads/hood-torsion-bar-adjustment.49352/#post-433649
https://e9coupe.com/forum/threads/hood-now-stays-open-but-misaligned.48782/#post-428050
https://e9coupe.com/forum/threads/hood-hood-torsion-bar-repairs-adjustments.47557/
trunk
https://e9coupe.com/forum/threads/trunk-spring-solution.48642/#post-426920