Damian's Project

[Damian]

Just thought I would detail my progress/ plans for my ride. I have a 2003 Jet Black ZHP with black leather and black cube 6MT. I purchased January 16, 2014 with 114,500 miles.

Completed:
Oil Mobil 1 (0W-40)
Trans fluid (RP)
Diff fluid (Titan Sintopoid)
AKG FCAB
Clutch stop mod (stopped at Lowe's OMW home from purchase for this specific purpose... lol)
Radio power button fix
Left rear window regulator
K&N FIPK
VCG
Beisan VANOS repair kit
Beisan anti-rattle
Clear corners (PO)
DISA (PO)
Coolant Expansion Tank (PO)
DME update (waiting at local indy for computer to finish :happyspidey)

To Do:
Brake Fluid refresh
Clutch fluid refresh
CDV-ectomy
Magnetic drain plugs
Rear diff bushings (already purchased AKG. notorious clunk has presented its ugly face)
Shocks/ struts
Rim re-finishing (curb rash from PO)
Fender turn signals (painted during fender bender courtesy of PO)
Paint Correction
EuroCharge
Headers?? (may not happen as they are not legal in CA)
3.38 diff swap (donor car is in my garage)
Suspension??

I'm sure I am missing something but will update as time goes. Sitting in my local indy like a kid in a candy shop waiting for my DME update to finish. This is my dd and I drive about 20-25k yearly so I spend alot of time in my car and want her to have nice things!

http://i965.photobucket.com/albums/ae137/Damian_Catalan/Mobile%20Uploads/IMAG1747_zpsqyoknwyt.jpg (http://s965.photobucket.com/user/Damian_Catalan/media/Mobile%20Uploads/IMAG1747_zpsqyoknwyt.jpg.html)

[Avetiso]

Nice! Another project. Let me know how you like the DME update.

[ELCID86]

Nice list of done and pending. I love the term "CDV-ectomy". You will like the results.


Thumbs, iPhone, Tapatalk.

[Damian]

DME Update definitely cleaned up the 2,800 power dip and improved throttle response. Unfortunately it did not turn my M54 into a jet engine.
http://i965.photobucket.com/albums/ae137/Damian_Catalan/Mobile%20Uploads/IMAG1750_zpsj4i4raye.jpg (http://s965.photobucket.com/user/Damian_Catalan/media/Mobile%20Uploads/IMAG1750_zpsj4i4raye.jpg.html)

Sent from my DROID RAZR using Tapatalk

[johnrando]

Good stuff! :like

[Damian]

Been a while since I updated this thing. So far I have had the following done:

Rear diff swap to 3.38 (definitely worth the shop time as the diff was free)
Paint correction and bumper fix (traded old 330i for this work)
Replaced side turn signals
Rear tires
20% Tint all around (now I look like a celebrity...lol)
Front License plate bracket (from Turner)

Will post new pic soon..

[Damian]

http://uploads.tapatalk-cdn.com/20160214/2d06090a3afb1d07404e7a37c2e30801.jpg

This was supposed to match stock alcantara and it doesn't come close. Gonna see how they look installed in the morning otherwise they're going back for a redo.

Sent from my XT1585 using Tapatalk

[ELCID86]

http://uploads.tapatalk-cdn.com/20160214/2d06090a3afb1d07404e7a37c2e30801.jpg

This was supposed to match stock alcantara and it doesn't come close. Gonna see how they look installed in the morning otherwise they're going back for a redo.

Sent from my XT1585 using Tapatalk

Looks way too light.


---
"ZHP is a garbage option anyway- just some cosmetic upgrades with a different cam and diff to claw back some of the performance lost fitting those hideous and heavy wheels. Any 330 with a 3.46 diff will smoke a ZHP every time. The whole Mafia thing reeks of childish behavior." - an e46fanatic

[Vas]

The headliner is not Alcantara btw

[az3579]

The headliner is not Alcantara btw

Judging by the wording used, it looks like he had it redone in alcantara, so... now it ​isalcantara. :)

[Damian]

I meant the alcantara of steering wheel/shift boot/e-brake boot, the headliner is still the same shadowline felt it came with. Definitely don't like these in the car so I'm pulling it this weekend and going to meet the owner at his suppliers shop Monday morning to order the correct one. I called them in advance and know they will have to special order it so hopefully I have em back by next weekend.
Ordered some goodies to install this weekend as well. Morimoto FX-R from TRS, Performance rear LCA since it seems one was bent and it wouldn't get within specs on last alignment.

Sent from my XT1585 using Tapatalk

[ZacharyMikel]

FX-R's for the win. Just installed mine, you'll love them. Post up some pics of this thing, I love black ZHP's!

[Damian]

FX-R's for the win. Just installed mine, you'll love them. Post up some pics of this thing, I love black ZHP's!
This retrofit kit is not as quick and easy as I thought it would be... Focusing on the prize though.

Sent from my XT1585 using Tapatalk

[Damian]

Night and day difference. Now I can see when headlights are on.
Pics of burnt bowls. They look just like every other pic I've seen.
2451124509
Pic of old light output, more like lack thereof.
24512
High beam activated
24513
These are definitely too light.
http://uploads.tapatalk-cdn.com/20160223/851d74f9567b41f44a23b1262d9f8e83.jpg

I'll post pics of new light output after I get some night pics. Used a parking garage to adjust beam after install.

Sent from my XT1585 using Tapatalk

[Damian]

Noticed I didn't include the UUC lightweight flywheel and organic clutch kit that was done with CDV-ectomy. Replaced thermostat and water pump (with aluminum fins) last month and expansion tank yesterday. Waiting on Z4M FCAB from FCP and ordered helical LSD through MFactory spring break sale. They're local so no shipping fees!

Sent from my XT1585 using Tapatalk

[BMWCurves]

Damn, the car will feel great after those upgrades. Envious of that MFactory LSD.

[Damian]

LSD is fun in the rain and keeps me firmly planted on the ground otherwise. Engine overheated again last spring and ever since the oil consumption has been ridiculous (1 qt every 350-400 miles). Did the 02pilot and managed to bring it down to 1 qt every 700 miles. A lot more reasonable but with 170k on the motor and a prior overhearing incident it was time to find a replacement since the last rebuild required milling the head down to min specs.
Picked up a new(er) motor over the weekend (109k miles). Turns out the guy is a mechanic and happened upon the donor ZHP in the I.E. pick a part. This guy had two e46 330ci, an AW e46 M3, a e46 540i and an e30 but the icing on the cake was a lift right smack in his driveway... It was a beautiful sight.

Back to the motor. Seems like the oil pan gasket and VCG need to be changed. While I'm there I will probably take care of oil pump nut, swap in m52tu oil scraper and new m54 piston rings and coupled with a low compression HG so i can slap the ESS TS2 on that I bought from Will.
Debating whether or not to go back to stock clutch/flywheel combo when I do the transplant. The UUC lightweight flywheel and clutch chatter is just not my cup of tea. I heard that I can swap in an M3 pressure plate with stock unit? Anyone have experience with that?

This kept happening last month every couple days.
http://uploads.tapatalk-cdn.com/20161114/c482954035e41d959533922fc7f95ce5.jpg

Feels so much betterhttp://uploads.tapatalk-cdn.com/20161114/54861a571cfe6959e946c2e65e65426c.jpg

Sent from my Droid Turbo2

[Sockethead]

I believe the the stock e39 M5 pressure plate will work but I haven't done it

[Damian]

So I purchased a used ESS TS1 kit with NIB stage 2 upgrade from Will a few months back and was supposed to start install this weekend. I couldn't wait, so I started yesterday. I'll post pics as I go.https://uploads.tapatalk-cdn.com/20170324/f9ae5fe79c186b09785f47ea19e83376.jpghttps://uploads.tapatalk-cdn.com/20170324/5040b1e40427c95d977dbd951613cbe4.jpg

Sent from my Droid Turbo2

[BMWCurves]

Awesome.

[Sockethead]

You're getting there... ;)

[Damian]

Slow and steady 😂
That sure is a tight fit!
https://uploads.tapatalk-cdn.com/20170325/a4f382287a2b805b0fc5f1e09e1de26f.jpg

Sent from my Droid Turbo2

[Sockethead]

Engine hoist: what a great idea! The wife and I muscled mine in. It was a nightmare

[RedAtom]

I will be watching this closely as well. I feel the need for moar powa!

Sent from my HTC6545LVW using Tapatalk

[Damian]

This was a SOB to get back in! Ended up tearing in a few spot but finally got it back on. Had to remove the panel behind cabin air filter and the windshield cowl to make it easier but it still required equal parts finesse and brute strength.
https://uploads.tapatalk-cdn.com/20170326/248704577386644bb5a28dfe1d436a15.jpg
I tested the setup with my K&N cone filter before putting it all back together. No leaks! It's a success!
https://uploads.tapatalk-cdn.com/20170326/201fa0adde66e1bb78f08809dd761959.jpg
Took it for a test drive but it was too dark to take pics of it all back together. Oh and I painted the lower mesh grill flat black "while I was there".
I plan to tackle the OPG tomorrow but we'll see how my back feels in the morning.

Sent from my Droid Turbo2

[Damian]

Engine hoist: what a great idea! The wife and I muscled mine in. It was a nightmare
I had planned for my wife to help but then she fell asleep after cleaning the house. When I realized she was asleep i had to figure it out. Luckily I had this and it was a yuuge help!

Sent from my Droid Turbo2

[Damian]

I will be watching this closely as well. I feel the need for moar powa!

Sent from my HTC6545LVW using Tapatalk
Do it!

Sent from my Droid Turbo2

[johnrando]

Cool. Looking forward to hearing about it.

Sent from my SM-G935V using Tapatalk

[Sockethead]

This was a SOB to get back in! Ended up tearing in a few spot but finally got it back on. Had to remove the panel behind cabin air filter and the windshield cowl to make it easier but it still required equal parts finesse and brute strength.
https://uploads.tapatalk-cdn.com/20170326/248704577386644bb5a28dfe1d436a15.jpg


I forgot about that thing... I tore mine in one spot too. Like you I had to remove the brand new cowl I had just installed a few days earlier. I hated that thing by the time it was done.

[Damian]

Oil pan gasket, trans fluid, trans mounts and M3 motor mounts swapped in last weekend. Driver's side mount was looking like PAC MAN. Odd thing is my engine didn't lurch as I'm used to seeing with bad motor mounts. It delayed my project a day since it was on a Sunday. Shifts are much smoother now. Not sure if it's the fresh trans fluid or the restored drivetrain geometry.https://uploads.tapatalk-cdn.com/20170412/b97add95761523adeb6caafac84dc31f.jpghttps://uploads.tapatalk-cdn.com/20170412/24b8dd727c673999f24634904f58da86.jpghttps://uploads.tapatalk-cdn.com/20170412/04886df6ed55071813c837c237665d5d.jpg

Sent from my XT1585 using Tapatalk

[Sockethead]

That last picture looks familiar. Your old mounts were definitely shot.... Mine were in really good shape when I swapped them for M3 mounts... go figure... I was really hard on the car for about 100K before swapping them. I thought they would of looked like yours.

Have you done you valve cover gasket? You want to make sure the engine is well sealed with that supercharger on there...

[Damian]

That last picture looks familiar. Your old mounts were definitely shot.... Mine were in really good shape when I swapped them for M3 mounts... go figure... I was really hard on the car for about 100K before swapping them. I thought they would of looked like yours.

Have you done you valve cover gasket? You want to make sure the engine is well sealed with that supercharger on there...
I was surprised at the condition but then again the mounts did have 176k on the clock so I guess it was their time. I did VCG 3 years ago when I bought the car. That was roughly 60,000 miles ago... man how time flies.

Sent from my XT1585 using Tapatalk

[Damian]

So my stock engine finally had enough. I recently switched to redline oil and I think the extra detergents loosened up the gunk holding it together because at 184k on the clock the engine had multiple misfires in cylinders 4,5&6. I pulled to plugs and lo and behold the piston head and plugs were coated in oil.

I pulled the motor and trans and will be replacing the motor with a spare ZHP motor I picked up some time ago. This will buy me some time to build the blown motor. Looking to do low compression Pistons, M52TU oil control piston rings (to eliminate oil consumption once and for all) and just replacing a lot of miscellaneous parts overall.

Trans shifter seal was leaking and Guibo was going out so I'm replacing those as well as shifter components and all the cooling hoses.

Any recommendations on Pistons or rebuild in general? I'm going to contact ESS to see if I can add more boost with low compression Pistons otherwise I may not go that route. Still undecided.
https://uploads.tapatalk-cdn.com/20170908/849a5f281665a2779138ea1391c7c8eb.jpghttps://uploads.tapatalk-cdn.com/20170908/8b3e59e5d2e04057d16cff710e802b8b.jpghttps://uploads.tapatalk-cdn.com/20170908/046f15c01e580020670c9d69e16dac73.jpghttps://uploads.tapatalk-cdn.com/20170908/610633cf4fd49682261c529e28fad344.jpg

Sent from my XT1585 using Tapatalk

[danewilson77]

So my stock engine finally had enough. I recently switched to redline oil and I think the extra detergents loosened up the gunk holding it together because at 184k on the clock the engine had multiple misfires in cylinders 4,5&6. I pulled to plugs and lo and behold the piston head and plugs were coated in oil.

I pulled the motor and trans and will be replacing the motor with a spare ZHP motor I picked up some time ago. This will buy me some time to build the blown motor. Looking to do low compression Pistons, M52TU oil control piston rings (to eliminate oil consumption once and for all) and just replacing a lot of miscellaneous parts overall.

Trans shifter seal was leaking and Guibo was going out so I'm replacing those as well as shifter components and all the cooling hoses.

Any recommendations on Pistons or rebuild in general? I'm going to contact ESS to see if I can add more boost with low compression Pistons otherwise I may not go that route. Still undecided.
https://uploads.tapatalk-cdn.com/20170908/849a5f281665a2779138ea1391c7c8eb.jpghttps://uploads.tapatalk-cdn.com/20170908/8b3e59e5d2e04057d16cff710e802b8b.jpghttps://uploads.tapatalk-cdn.com/20170908/046f15c01e580020670c9d69e16dac73.jpghttps://uploads.tapatalk-cdn.com/20170908/610633cf4fd49682261c529e28fad344.jpg

Sent from my XT1585 using TapatalkRead post 89 and beyond and link up with Wyatt.

http://www.zhpmafia.com/forums/showthread.php?t=8597

Sent from my S8+

[ELCID86]

You had me at "extra motor..."!


---
"ZHP is a garbage option anyway- just some cosmetic upgrades with a different cam and diff to claw back some of the performance lost fitting those hideous and heavy wheels. Any 330 with a 3.46 diff will smoke a ZHP every time. The whole Mafia thing reeks of childish behavior." - anonymous E46 fanatic

[Sockethead]

ESS used to have a TS3 kit which includes low compression pistons, a smaller pulley, tuning but I don't see it on the website.
If you're a member over at E46F they have a really knowledgeable group in the FI forum