Installing Koni struts in an E36 can greatly improve handling and ride quality. The installation process involves modifying the stock struts to accommodate the Koni inserts, making it an attainable project for DIY enthusiasts.

Understanding the specific steps and having the right tools will streamline the installation and help avoid common pitfalls.

Many car enthusiasts struggle with confusing instructions and may feel overwhelmed by the task. With clear instructions and resources available, like videos and guides on the Koni insert process, anyone can tackle this upgrade with confidence.

This blog post will break down the installation steps in a simple way, ensuring a smooth experience for those looking to enhance their E36.

Whether it’s a daily driver or a track-focused car, upgrading to Koni struts is a popular modification. Proper installation can lead to better performance on the road and track. Readers will find valuable insights to make this upgrade successful and enjoyable.

Tools and Materials Required

To install Koni strut inserts in an E36, specific tools and materials are necessary for a successful installation.

Essential Tools:

• Ratchet Set: Necessary for loosening and tightening bolts.
• Spring Compressor: To safely compress the springs while disassembling the strut.
• Breaker Bar: Helps to break loose stubborn bolts.
• Drill: Required for making modifications to the strut.
• Drill Bits: Both 1/8” (or 3mm) and 1/2” (or 12-13mm) bits are needed.
• Hammer and Center Punch: Useful for marking drill points.

Additional Supplies:

• Koni Strut Inserts: These are the main parts being installed.
• Lubricant: Helps with the assembly process.
• Safety Glasses: Protects eyes during drilling and assembly.

Optional Items:

• Impact Wrench: Makes it easier to remove bolts quickly.
• Round File: Useful for smoothing drilled holes.

Having the right tools and materials ready ensures the installation process is straightforward. It promotes safety and efficiency while working on the E36 strut system.

Safety Precautions

When working on a vehicle, safety should always come first. Proper use of tools and protective gear can reduce the risk of injury significantly.

Attention to detail during preparation and execution ensures a safer working environment.

Vehicle Jack and Stand Usage

Using a vehicle jack correctly is crucial for safety. Always choose a jack that is rated for the weight of the car.

If working on an E36, make sure that the jack can handle its weight, typically around 2,800 to 3,000 lbs.

Before starting, position the jack under the designated lifting points found in the owner’s manual.

Once elevated, never rely solely on the jack to support the vehicle. Always use jack stands after lifting. Position them under the frame, ensuring stability.

Avoid using makeshift supports or blocks that are not designed for this purpose.

Check that the ground is level and solid to prevent slipping or tipping. Regularly inspect jacks and stands for signs of wear or damage.

Personal Protective Equipment

Personal protective equipment (PPE) is essential during any automotive work.

Workers should wear safety goggles to protect their eyes from flying debris. Gloves are important to shield hands from sharp edges and chemicals.

Hearing protection is advisable, especially if using power tools.

Long sleeves and pants can prevent cuts and scrapes. Steel-toed boots can protect feet from heavy objects that may drop.

It’s also wise to keep a first aid kit nearby. In case of minor injuries, having supplies on hand can make a difference.

Remember, taking these precautions enhances safety and helps prevent accidents.

Vehicle Preparation

Proper vehicle preparation is essential for effective Koni E36 strut installation. Following the right steps ensures safety and smooth progress through the installation process.

The key areas to focus on are wheel removal, accessing the strut assembly, and inspecting the strut tower area.

Wheel Removal

Begin by parking the vehicle on a flat surface and engaging the parking brake.

It’s important to loosen the lug nuts on the wheel before lifting the car. This makes it easier to remove the wheel once the vehicle is elevated.

Next, use a jack to lift the vehicle, positioning jack stands securely to support it.

Once the car is safely elevated, fully remove the lug nuts and take off the wheel.

Store the lug nuts in a safe place to avoid losing them during the installation.

This step provides clear access to the strut assembly, making the next phases of the installation smoother.

Accessing the Strut Assembly

To reach the strut assembly, locate the strut upper mount under the hood. It may require removing other components, such as plastic covers or air intake parts, to gain proper access.

At the same time, check the lower part of the strut near the suspension. It is held by bolts that need careful removal.

Make note of any components removed for reinstalling them later.

Be cautious while handling the strut assembly. This area can be tight, and maintaining proper control will ease the installation later.

Strut Tower Area Inspection

Before proceeding with the installation, Inspect the strut tower area for rust, damage, or any signs of wear.

This is crucial as any structural issues can lead to performance problems once the new struts are in place.

Use a flashlight for better visibility and clean the area of dirt and debris. This ensures a proper fit for the new struts.

Taking the time for this inspection can save significant trouble in the future. If any issues are found, consider addressing them before proceeding with the installation.

Removing the Old Strut Assembly

Removing the old strut assembly is crucial before installing new Koni struts. This process involves disassembling the strut from the vehicle and carefully compressing the coil spring for safe disassembly.

Disassembling the Strut from the Vehicle

To start, securely lift the vehicle using jack stands.

After that, remove the wheel to gain easy access to the strut assembly.

Next, disconnect the brake line and any other components connected to the strut.

Loosen and remove the bolts that attach the strut to the steering knuckle. It is often helpful to use a penetrating oil if the bolts are stubborn.

Once the knuckle is free, remove the top mount bolts located within the engine bay.

Carefully pull the strut assembly out of the vehicle. Inspect all components for wear or damage.

Properly dispose of the old strut assembly if it will not be reused.

Coil Spring Compression and Strut Disassembly

Before disassembling the strut, it is essential to use a coil spring compressor.

This tool compresses the spring, reducing tension and allowing safe removal from the strut assembly.

Place the compressor evenly on both sides of the coil spring, tightening slowly and evenly.

Once the coil is compressed, remove the top nut using a wrench. Keep in mind that the spring will still be under tension.

After the top nut is off, carefully release the coil spring compressor.

With the spring removed, the strut can be disassembled. Remove any remaining components, like the rubber mounts and bump stops.

This ensures that the new Koni strut inserts will fit properly into the assembly later on.

Assembling the New Strut

Assembling the new strut is a crucial step in the installation process. Proper attachment and mounting ensure optimal performance and safety.

The following key tasks are essential for a successful assembly.

Attaching the Spring to the Strut

Start by placing the spring onto the strut. It should fit snugly against the spring seat at the bottom.

Ensure the ends of the spring align properly with the seat’s notches. This alignment is vital for stability during operation.

Next, use a spring compressor to safely compress the spring. This tool allows for easy handling and reduces the risk of injury.

Once compressed, position the top of the spring over the strut mount.

Secure the spring by attaching the top mount to the strut.

Check to see that the mount aligns properly with the strut assembly. Tighten the nuts to the manufacturer’s specifications.

This ensures that the spring will perform well under load.

Mounting the Strut Bearing

After the spring is successfully attached, the next step is to mount the strut bearing.

Position the strut bearing onto the top of the strut assembly. Make sure it fits flush against the spring mount.

Using the provided hardware, secure the bearing in place.

It is crucial to follow the manufacturer’s torque specifications for this step. This will prevent premature wear or failure of the components.

Finally, double-check the positioning of the strut bearing.

Proper alignment is necessary for smooth steering and suspension operation. Ensuring everything is tight will lead to better handling and increased safety on the road.

Installing the New Strut Assembly

Properly installing the new strut assembly is crucial for vehicle safety and handling performance.

The process involves careful positioning in the wheel well and secure bolting to the vehicle, ensuring everything fits correctly.

Positioning in the Wheel Well

First, align the new strut assembly with the mounting points in the wheel well.

It is important that the strut is in the correct orientation, with the top mount facing upward. Make sure that the bottom of the strut is securely positioned in the wheel hub.

Before positioning, inspect the area for any debris or old components that may interfere.

The strut should slide easily into place. Once aligned, do a final check to ensure the strut is level.

This helps in maintaining proper suspension geometry and ensures a smooth ride.

Bolting to the Vehicle

After positioning, the next step is to bolt the strut assembly to the vehicle.

Begin by securing the bottom of the strut to the wheel hub using the provided bolts. Typically, this requires a torque wrench to ensure the bolts are tightened to the manufacturer’s specifications.

Next, move to the top mount. Align it with the holes in the strut tower and insert the bolts.

Ensure that all bolts are tightened securely.

A good practice is to follow a crisscross pattern during tightening, which helps to evenly distribute pressure.

Check each bolt again to confirm they are tightly fastened.

Post-Installation Checks

After installing Koni struts, it is essential to perform specific checks to ensure everything is in proper order.

This section covers critical areas like torque specifications and the importance of alignment and suspension tests.

Torque Specifications

Correct torque specifications are crucial for safety and performance.

Each bolt and nut should be tightened to the manufacturer’s recommended torque values.

This ensures that everything remains secure during operation.

Common torque specifications for E36 strut components include:

• Top strut nut: 50 Nm (37 ft-lb)
• Lower strut bolts: 80 Nm (59 ft-lb)
• Sway bar link: 30 Nm (22 ft-lb)

These values are essential for maintaining the integrity of the installation.

It is advisable to use a calibrated torque wrench to achieve accuracy.

Rechecking the torque after a short driving period can help identify any loosening that may occur.

Alignment and Suspension Test

After the installation, the vehicle’s alignment must be verified.

Misalignment can lead to uneven tire wear and affect handling.

It is recommended to take the car to a professional alignment shop.

A suspension test is also important.

This involves checking for any strange noises, excessive bouncing, or other abnormal behavior.

Take note of how the vehicle responds during test drives.

The technician should look for:

• Proper height: Ensure the car sits at the correct height.
• Smoothness: The ride should feel controlled and steady.
• No leaks: Inspect for any oil or fluid leaks around the struts.

Wheels Reinstallation and Lowering the Vehicle

Once the Koni struts are installed, it is time to reinstall the wheels. This step is essential to complete the suspension upgrade.

1. Align the wheel with the hub.
2. Insert the wheel bolts. Hand-tighten them first to ensure proper placement.
3. Use a torque wrench to tighten the bolts to the manufacturer’s specifications. This ensures safety and performance.

After securing the wheels, it is time to lower the vehicle. Ensuring safety during this procedure is vital.

• Check surroundings. Make sure there are no obstacles or tools in the way.
• Slowly lower the vehicle. Use a jack to lower it evenly to avoid tipping.

Once the car is back on the ground, they should check the ride height. Adjustments may be needed for optimal performance.

Important points to remember:

• Ensure all nuts and bolts are tightened properly before taking the vehicle for a drive.
• Inspect the wheel alignment after the installation. Misalignment can affect handling and tire wear.

Test Drive and Fine-Tuning

After installing Koni strut inserts, it is essential for the driver to assess handling and inspect for noise and vibration. These checks can help ensure that the installation has been successful and that the vehicle performs as expected.

Handling Assessment

During the test drive, the driver should focus on the vehicle’s handling characteristics.

This includes responsiveness in steering and overall stability.

It is important to:

• Test various road conditions: Drive on smooth roads, bumps, and corners.
• Check body roll: Notice if the body leans excessively during turns.
• Evaluate braking performance: The vehicle should stop firmly and without pulling to one side.

Additionally, the driver should feel for changes in feedback and adjust driving style accordingly.

Any significant difference in handling might indicate further adjustments are needed.

Noise and Vibration Inspection

Next, the driver should assess for any unusual noise or vibration from the suspension. This can reveal potential issues with the installation.

Key points to inspect include:

• Listen for clunking or rattling sounds: These may indicate loose components.
• Monitor vibration levels: Excessive shaking during driving or at rest can signal problems.

It is also advisable for the driver to check the struts visually while stationary.

Inspect for leaks or signs of wear. Proper functioning should result in a smooth ride with minimal disturbances.

Addressing any abnormalities promptly can help maintain vehicle integrity.

Maintenance Tips

Maintaining KONI struts is important for optimal performance.

Regular checks can help extend the life of the suspension system.

• Inspect Regularly: Check for any signs of leakage or damage. Worn struts can cause uneven tire wear and affect handling.
• Torque Specifications: Ensure all bolts are tightened to manufacturer specifications. Loose bolts can lead to excessive wear or failure.
• Alignment: After installation, proper alignment is crucial. Misalignment can cause handling issues and increased tire wear.
• Replace Damaged Parts: If any components are worn or damaged, they should be replaced promptly. This includes shock mounts and bushings.
• Clean Struts: Keep the struts clean and free from debris. This helps prevent corrosion and extends the life of the components.
• Monitor Ride Quality: Pay attention to how the vehicle rides. A noticeable change in ride quality can indicate issues with the struts.