This latest production BOSCH 0 265 200 040 found in 1992+ model years features a fundamental internal solenoid engineering overhaul. The solenoid traveler valve is upgraded and made in polished chromoly steel. The larger traveler has more magnetically reactive mass and this revised design allows for moving the return spring inboard and nearly tripling in size over its predecessor design. The larger spring returns the valve to rest faster and eliminates the possibility of sludge blocking the springs movements. Finally the plastic caged internal bearings present in the earlier design have been completely eliminated as the revised design does not need or benefit from them, providing one less failure point.
The solenoids on this pump are specific to the 040 Super series of pumps. The upper manifold plate has lost the bosses for top facing ports found on other models and now sports a sleek upper top plate.
The primary difference between the late 040 and the mid 040 is the addition of cosmetic sleeves made of aluminum that cover the solenoid frames. These are finished in a polished surface treatment but can be offered in brushed by request. The sleeves are often not salvageable from core pumps due to galvanic corrosion and as such they do carry a modest premium over non sleeved pumps.
The cover shroud and chassis wiring hold down are secured with T15 Torx screws
Each core pump is 100% torn down and each component carefully inspected for suitability to reuse. Imperfect parts are discarded. Approximately 1 in 5 core pumps are 100% rebuildable once fully processed. 80% of pumps require donor parts from inventory to complete to an acceptable standard. Broken springs, sheered retaining hardware, pitted ball bearings, seized solenoid and corroded sealing surfaces are extremely common reject causes.
After passing initial inspection all components, internal and external, aluminum, steel plastic and rubber are ultrasonically cleaned to remove the sludge encumbering the inner workings. The majority of deposits are removed at this point. Components are reinspected and those that do not clean up are discarded. An additional 20% of components are rejected at this stage in the process leaving only the finest parts suitable for safe reuse.
Aluminum bodies and components are vapor honed to a high quality surface finish that is both cosmetically pleasing and durable. The wet blasting peens and seals the surface to a luster approximating the appearance of fresh cast aluminum. These units are NOT painted. Steel parts are hand polished or vapor honed as applicable to ensure free and clean operation of moving internal parts critical to reliable operation.
All steel parts used in the pump subject to direct contact with the environment and visual appearance are chemically stripped of existing plating, machine polished to a high sheen and plated with yellow zinc chromate to replicate the original finish and appearance. The plating looks great and will serve to protect the steel from corrosion for years to come as the original plating did its best to since produced.
With a massive inventory of hand cleaned, polished, vapor honed and plated parts along with replacement seals each pump is built to exacting standards of perfection. Only the nicest components go into each rebuilt unit. With each pump you can be assured it will reliably perform day after day on your show car, daily driver, or SpecE30....and not to mention the cosmetic appearance that goes along with a selection process this detailed.
Once completed each pump is tested on the bench before being shrink wrapped for inventory or shipping. Coil winding impedance, motor inrush and operation amperage draw verified within anticipated spec. Solenoids cycled for validation, and finally the hydraulic system sealing is tested to 100psi holding pressure.Once tested to satisfaction plastic port plugs are installed and a replacement anti-tamper cap is pressed into place for security.
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E30, E28, M3 & M5 are registered trademarks of BMW AG, Munich, Germany.
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