BMW E30 Corsa Steering Linkage Guide & PAS Line Routing for RHD Steering Rack Conversion | 040

BMW E30 Corsa Steering Linkage Guide & PAS Line Routing for RHD Steering Rack Conversion | 040

In this E30 build video I create a slim E30 steering linkage using a Vauxhall Corsa C steering linkage (or Holden Barina if you're an Aussie), and bend the Right-hand drive (RHD) BMW power steering lines to meet up with my Z3 steering rack conversion.

Here's what I use in this video:
Corsa C Steering Linkage: https://ebay.us/6u2GQp
Map Gas Blowtorch: https://ebay.us/1WipXe
Chisel and punch kit: https://ebay.us/cxWsHA
CV Grease: https://ebay.us/SFB9En
14mm spacers (M10 clearance): https://ebay.us/W6Pyky
Z3 steering rack rebuild service: https://ebay.us/wj9hqU
Purple tag steering rack rebuild service: https://ebay.us/GamWq6

First off, if you're interested in doing the whole Z3 or Purple Tag steering rack conversion to your E30, you need to start at the previous video where I outline how to fit the Z3 rack up with 14mm spacers:    • Best E30 Steering Rack Swap [Z3 2.7 v...  

Once you've got to that point, the steering linkage AKA steering knuckle, and routing of the original PAS lines will be your next obstacle.

In theory, you're supposedly able to continue using the standard E30 steering knuckle when doing a steering rack conversion, and that is somewhat correct, but I found that the steering linkage was slightly too long, meaning it was taking up the entire steering rack and steering column splines with absolutely no wiggle-room. I could imagine this to be an issue once there is heat expansion at play thanks to proximity to the exhaust manifold.

But further to that, I'm planning to do an M52 engine swap so using the original E30 steering coupler is not an option for me thanks to its width obstructing the routing of the exhaust pipes. In fact, if you have any kind of aftermarket exhaust manifold (headers), even with M40 or M20 engine, you'll run into problems with the original E30 steering linkage fouling it.

When doing a steering rack conversion for RHD E30s, you'll find that the requirements for bending the original PAS lines is not well documented at all, and there's barely one photo on the entire internet showing how the RHD lines need to be routed to meet up with the steering rack swap whether Z3 or Purple Tag. So this video involved a bit of experimental trial and error to solve it. But luckily it was successful.

Regarding the Vauxhall Corsa steering rack mod for E30, this is a great cost-effective way to get a slimline E30 steering rack. It involves modifying the Corsa steering coupler to have the E30 steering column splined end instead. Here are the steps:

1. Remove non-splined end of Corsa C steering knuckle with angle grinder
2. Knock the stakes back on the E30's steering column end bearings
3. Press out the bearings on the E30 steering coupler with two sockets and a vise
4. Fit the E30 end to the Corsa linkage, regrease and press the bearings back in place
5. Restake bearings
6. Grind out key spline from steering rack end of the linkage
7. Replace steering rack side retaining bolt with an M6 shouldered 35mm cap-headed bolt and nut

You will need to be especially careful with the bearings, as you see in the video, they are very easy to damage, and you can end up with them being very notchy which would obviously be no good for your BMW steering feel. Luckily your E30 steering linkage will be trash with an end missing, so you've got a few spare bearings to go at if needs be.

With it fitted to the car, you will find the Corsa linkage retaining screw won't fit with the notch on the steering rack splines. I was originally planning to drill the hole out wider and use the E30's nut/bolt. But I found a nice M6 shouldered bolt to use as a much better alternative to secure the steering linkage to the rack.

The E30's original power steering lines are quite different to the Z3 ones, and thus do not naturally line up to the ports on the Z3 steering rack which is unfortunate. I think this is much less of an issue with LHD cars thanks to the lines being a different design with more rubber flex hose. But with RHD E30's, it's a pretty drastic difference.

The low-pressure return line ended up only needing a minor bend, and I had to bend the hard lines on the Z3 steering rack for a bit more clearance too. But the high-pressure PAS line needed rerouting entirely around the back of the subframe. Using the original high-pressure line seemed like it would be impossible until I worked that out.

To bend the lines you need to apply a lot of heat, I used map gas for this which worked quite well, bending the lines with the bench vise.

For more helpful how-to guides: https://www.spannerrash.com/

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