A ZSP and some Elbow Grease [Archive] - BMW E46 330 ZHP For Sale Forum

View Full Version : A ZSP and some Elbow Grease

///Mvious

10-07-2016, 05:30 PM

Hi fellow Mafia crew :hi...I've been a member for a couple years, and an e46 owner for about 5, but haven't posted here much. I frequent the forum though and have been following a few builds for the last few years....So, I thought I'd document my latest pickup. A couple months ago, I picked up a slick-top 2002 ZSP sedan to take on the daily duties. Not exactly my favorite interior color, and I would have preferred a ZHP, but I got a great deal on this one...

A bit about the car:
Optioned with xenons, 18' wheels, and sport package...one owner, 90k mi., 3k mi. Castrol Synthetic oil change interval, no accidents, great paint, an SC car since day one, and to top it off, no sun roof. Despite the solid oil change interval, she was in need of TLC. The PO had replaced the Thermostat at 65k, the diff fluid once, fuel filter once, all window regulators, valve cover at 85k, and had installed a couple of extras (UUC SS kit w/ DSSR, Bavauto High performance coils). Other than that she was running original equipment for the rest of the cooling system, suspension, and the entire braking system including the fluid!

So I drove her home, and placed a couple big orders on parts (New FCP Euro Fan here btw...shout out to those guys!) and got her up on jack stands. Being an Accounting/Finance guy with a wife and two young daughters, time is limited, but I must say, for the six weeks she was up on stands, I enjoyed giving her new breath! I'll be documenting the work I have completed as I have time, and still have many projects on the horizon (brake and suspension overhauls will be next) that I will then document. Anyway...long intro...here are a couple iPhone pics the day I picked her up...
2750227503

Karl Lazlo

10-07-2016, 05:32 PM

Niiiiiice! Let's hear some love for the ZSP! Nice wheels, the same came on my 2003 ZSP when I grabbed it 10 years ago.

slater

10-07-2016, 06:43 PM

very cool - i love those wheels! and, TiAg is sweeeeet. looking forward to more details on the refresh! :cheers

holyc0w

10-08-2016, 05:44 AM

Nice titansilber :)

Looking forward to following your progress.

ELCID86

10-08-2016, 06:05 AM

Thanks for sharing. (BTW, my wife is from Sumter and I'm from Aiken).

Sent from my iPhone with TaT.

///Mvious

10-08-2016, 05:38 PM

Thanks Guys! Fun project so far. I have an e46 coupe (seen in my sig though I'm running style 68s currently) which has been nice to periodically reference!

Shawn - A few years back i did some work in Aiken (auditing Carlisle Tire & Wheel). My wife is from Augusta (her folks still live there) so I've driven through there many a time!

Oli77

10-08-2016, 06:42 PM

Nice to see you come out of the woodwork!
From a ZSP hunger (who secretly thinks a zhp car is hidden under that skin).

johnrando

10-10-2016, 06:37 PM

Nice!

Sent from my SM-G935V using Tapatalk

///Mvious

10-11-2016, 05:24 PM

When I went to take a look at it, the owner was a real nice, laid back, understanding guy. He had a Bentley manual and had done maintenance on the car and fixed a few items noted above, so he knew a bit about it. I was going to ask, but before I could he offered to pull it up on the ramps so I could take a look underneath. He had told me before that it had an insignificant oil leak, which I wanted to take a closer look at. I pulled off the belly pan and it was difficult to tell if it was coming from the OFHG or the oil pan gasket. Looking in from the top of the motor, I could tell that the OFHG was likely the cause. Other than that, the high pressure steering hose looked like it might have a weep...but that could have been from the oil. Anyway, I got it off the ramps and took it for a spin...It felt solid...no steering vibration...brakes actually felt good, and the motor sounded good and pulled well. Now I've grown used to my garage queen 330ci, which has a few performance mods (that actually make a little performance difference and a big sound difference) including headers, Dinan Stage 2 tune, SuperSprint X, mid, and rear resonator, Dinan Long tube Intake and a few others, so this car didn't sound close, and mental or not, didn't feel nearly as quick. I wasn't surprised there though, I've driven a couple stock ZHPs and they didn't feel like my 330 either...I know...I know...alot of it is the sound and the Dinan tune, which seems to give full throttle at half or 3/4. The Interior was good...I could tell it had sat outside a good bit, but this was going to be a driver, so I wasn't looking for perfection...needless to say I wanted it. I asked him what he would take cash today...he thought for a second and came down more than I thought he would, but then of course I offered little less :)...and he took it! I was surprised, but quickly started plotting the resurrection of this girl!

Even though he had replaced the thermostat not long ago, I knew I would go ahead a do the entire cooling system (along with as many cooling/heater core hoses as I could do without taking off the intake manifold). The battery was replaced about 5 years ago, so put a new one of those in the basket. The windshield cowl was chipping away in several areas, so add that to the cart. The Alternator had never been replaced, so would have to get one of those (my 330ci at 10 years old and 37k miles left me stranded). I had some Vanos seals and anti-rattle kit in my garage waiting for my ci, so thought I'd go ahead and do that while I had her up on stands. Since I was in there, had to do the VCG (had one of those in the garage as well). Oh, and the pulleys and tensioners were all original (as were the belts), so I would do those as well. Since the high pressure PS lines might be weeping, I'd replace those as well as the reservoir and low pressure hoses. The Intake boots were original too...so would have to do those, and of course I'd clean the TB, ICV while I was at it. The DISA was original, so just for safety sake, I ordered one from Dr. Vanos. hmmm...I think that was all I planned at first...of course I'd detail it, and Leatherique the leather...brakes and suspension bits would be next on the agenda. So started the journey. I started tearing her down:

e46 buds! :cheers
27596

2759727598

OFHG definitely causing issues!
27599

More to come......

Karl Lazlo

10-11-2016, 05:45 PM

Niiiiiiice!

BMWCurves

10-11-2016, 05:46 PM

All great stuff!

danewilson77

10-13-2016, 04:03 PM

All great stuff!
+1

S7 Edge, out

///Mvious

10-14-2016, 04:52 AM

With the long list of parts I knew I needed, I started refreshing my memory on the brands I wanted and researching for the best deals. I've primary ordered from ECS Tuning, but have given others some business along the way with the ci (Tischer, BavAuto, Turner, RM European). Some are probably familiar, but Mango over on e46Fanatics has compiled a lot of helpful information and that is how I found FCP Euro...until then, I had never heard of them. They offer a "Mango" cooling kit that had the right parts and the price was right...not to mention they offer free shipping over $49 (that wasn't going to be a problem!)...Lifetime replacement on all their parts (including wear and tear parts) :scratchinghead...and a convenient return policy...what got me was the "if we wouldn’t put it on our cars, we won’t sell it to you"... I've taken a chance on a part or two in the past with non EO/Genuine BMW parts and had issues. Anyone else on here heard of them? so I gave them a shot.
27630

Quick shipping, VERY well packaged and all the parts were there!

Lots of fun to be had!

san

10-14-2016, 04:59 AM

BMWCurves

10-14-2016, 06:07 AM

Yup, FCP Euro is pretty good on prices, customer service, and warranty. I bought most of the parts for my sister's cooling system refresh through them. Bought individual parts rather than any kit (cheaper at the time of purchase).

They include even wear parts like wiper blades. I plan to see how their lifetime warranty works when they stop working.

Sockethead

10-14-2016, 06:21 AM

Did you use the "mango discount"?

Aeternalis

10-14-2016, 06:44 AM

Anyone else on here heard of them?

FCPEuro is my go-to site for parts. Their interface is better than any of the other big boys (IMO) with clear distinctions between Genuine, OEM, and Aftermarket brands. Returning things is also quite painless.

Free shipping and the Lifetime Guarantee are also huge draws for me, especially since many things (suspension, cooling system, etc) on our cars need replacing regularly.

///Mvious

10-14-2016, 06:45 AM

Did you use the "mango discount"?

Yes sir!...well on my 2nd and 3rd orders (needed parts list grew once I was in there)...on the first I used the 10% first time buyer discount.

az3579

10-14-2016, 07:32 AM

FCPEuro is my go-to site for parts. Their interface is better than any of the other big boys (IMO) with clear distinctions between Genuine, OEM, and Aftermarket brands. Returning things is also quite painless.
.

Funny you say that - the user interface is something I wish they would change. I find it much harder to find things compared to ECS Tuning's website.

Aeternalis

10-14-2016, 07:53 AM

Funny you say that - the user interface is something I wish they would change. I find it much harder to find things compared to ECS Tuning's website.
I look my parts up on RealOEM or Google then plug the numbers into the search field near the top of the page. All the Genuine, OEM, and Aftermarket results pop up in a list. Pretty straightforward for me.

I rarely look through categories of parts (what they have listed near the left side of the page) on any website since I know their inventories are so massive.

Sent from my Nexus 6 using Tapatalk

///Mvious

10-14-2016, 07:55 AM

az3579

10-14-2016, 09:43 AM

I look my parts up on RealOEM or Google then plug the numbers into the search field near the top of the page. All the Genuine, OEM, and Aftermarket results pop up in a list. Pretty straightforward for me.

I rarely look through categories of parts (what they have listed near the left side of the page) on any website since I know their inventories are so massive.

Sent from my Nexus 6 using Tapatalk

Part numbers are fine anywhere, but in the instance when you don't have a part number handy, looking stuff up is a real pain. Searching for the part via its name doesn't always turn up relevant results.

///Mvious

10-21-2016, 06:17 PM

The tear down - After removing the intake box and boots, I removed all the cooling system bits...then came the belts, tensioners, pulleys and alternator. I then sucked up as much of the power steering fluid as I could out of the reservoir and removed that and the hoses connected. Next, I got at the oil filter housing...I haven't replaced OFHG on my coupe yet, so this was my first time...not too bad...then off with the valve cover and vanos unit. The VCG and Vanos was another first...pretty easy, but takes a bit of time. Then I removed the PS pressure hoses...the one from the rack to the cooling coil (https://www.fcpeuro.com/products/bmw-power-steering-pressure-hose-32411096494) and then the one from the pump to the rack (https://www.fcpeuro.com/products/bmw-power-steering-pressure-hose-325i-328i-330ci-330i-32416764725). These weren't too bad, but removing the old rack to the cooling coil hose was a pain (especially without the special tool)...

Tearing her down was a dirty job (I've been spoiled working on a low mileage garage queen)...and every hose I touched had seen better days...each would disintegrate a bit when handled, especially the vacuum hoses. I wasn't planning on it, but I purchased 5 meters of 3.5 X 7.5 mm silicone vacuum hose (https://www.fcpeuro.com/products/bmw-vacuum-line-5-meter-11727545323) and replaced all I could get my hands on! I couldn't put it back together with those hoses that were wasting away. Here is a pic of these nasty hoses (with new pieces cut to size accompanying):
27760

Being a bit anal as it comes to cleanliness, as I removed parts, I got in there with some green clean and a microfiber. I was a bit overwhelmed at first, but gradually making progress and seeing the huge transformation, I was encouraged.

After pulling all the parts off, I spent some cleaning. The OFH and PS pump was difficult to clean...just not easy to handle and keeping all the holes plugged. I managed though...not perfect, but much better.

Before:
27763

After:
27764

Sorry for the crappy pics.

BMWCurves

10-21-2016, 09:20 PM

Damn, that's a whole slew of things. Nice work.

Oli77

10-22-2016, 04:41 AM

That's clean! Good feeling.

RUS_ZHP

10-23-2016, 09:42 AM

holyc0w

10-23-2016, 11:15 AM

I noticed an oil pan on the picture, did you get from Amazon? How do you like it? I think I saw that one and thinking to upgrade my crappie one that I bought few years ago

Sent from my SM-G900V using Tapatalk

I bought this one and it's working out pretty well:
https://www.amazon.com/gp/product/B009IISLLU/

///Mvious

10-23-2016, 01:38 PM

Good job and a lot of boxes with new parts, that's always existing!
I noticed an oil pan on the picture, did you get from Amazon? How do you like it? I think I saw that one and thinking to upgrade my crappie one that I bought few years ago

Sent from my SM-G900V using Tapatalk

Walmart baby! It works great...I used to use another Walmart catch container (had multiple) with a snout (for lack of better description) and the cap would always break...this one is durable

RUS_ZHP

10-23-2016, 03:19 PM

Thanks. I also have one from Walmart and cap is always leaking, which makes transportation very inconvenient

Sent from my SM-G900V using Tapatalk

///Mvious

01-08-2017, 09:31 AM

Been busy lately with the holidays, a brake overhaul (that I'll document later) and life as usual...but picking up where I left off...

After cleaning up the Oil Filter Housing and replacing the gasket (which was very brittle), I re-installed with a new Oil line and banjo bolts. Not difficult, and I was careful to make sure that all the bolts were slowly tightened at the same rate and torqued to spec, but I was still a little worried that it wasn't sealed properly. I had heard of folks putting it all back together and having another OFHG leak. It was difficult to see the mating surface all around, but in the end it was fine and no leaks after driving for a couple months now!

I then began the reinstall of the Power Steering Hoses and reservoir. For this I purchased the FCP Euro Basic Overhaul Kit (https://www.fcpeuro.com/products/bmw-power-steering-kit-basic-e46-e46pskit1) along with the pressure hoses (https://www.fcpeuro.com/products/bmw-power-steering-pressure-hose-325i-328i-330ci-330i-32416764725) & (https://www.fcpeuro.com/products/bmw-power-steering-pressure-hose-32411096494) and the banjo bolts (one with a check valve) and fresh washers. This piece wasn't bad...I was a bit confused at first since this hose (https://www.fcpeuro.com/products/bmw-power-steering-pressure-hose-325i-328i-330ci-330i-32416764725) did not install like the one that came factory on the car. The factory hose ran parallel to the ground while this new design runs perpendicular. Took me a while to realize that I did have the correct part. Anyway, I installed all the hoses and the reservoir and refilled with some fluid (more fluid to come once the PS pump ran after starting).

On to installing the new Alternator, new idler pulley securing bolt and idler pulley. I secured down to spec and was now ready to install the water pump, tensioners, pulleys and belts. As mentioned earlier, these were all original (90k mi. and 14 years old) so needless to say they were in need of replacement:
28642

New Water pump and water pump pulley:
28643

I sold the water pump that came with the FCP Mango kit which was a Saleri and opted for the Stewart...I'm sure the Saleri would have been just fine, but I've had a Stewart on my coupe for some time now and have like it!

Now for the new main belt hydraulic tensioner and A/C Belt tensioner, pulleys, & new hardware. I used the FCP Kit (https://www.fcpeuro.com/products/bmw-accessory-belt-tensioner-assembly-11287838797-1-2) an an INA A/C belt tensioner (https://www.fcpeuro.com/products/bmw-a-c-belt-tensioner-11281433571-1). I installed and torqued to spec.

2864428645

Looking fresh!

Gotta run...wife is going stir crazy with the girls...I'll be back at some point:cool

danewilson77

01-08-2017, 09:51 PM

Great work.

johnrando

01-11-2017, 10:10 AM

Sweet. I need to install my Stewart.

///Mvious

05-11-2017, 12:18 PM

I seem to have a difficult time sitting down and documenting the progress...anyway...picking up where I left off...
I buttoned up the cooling system overhaul with the expansion tank (OE), upper and lower coolant hoses (Rein), a Behr Radiator, Cooling fan temp switch (OE), coolant return hose (Rein), heater hose (upper and lower) (Rein), coolant level sensor (OE) and BMW coolant with Redline Water Wetter...using the Schawaben Coolant Refill/Air Purge Tool...works great!
2990829909299122991329918
Looks about right!

Of course the intake books needed refreshed I went with Mishimoto Silicone boots...not real happy with the fitment, but I made them fit without cutting, there is a good bit of forward pressure on the intake box though, so I'll eventually trim them for a better fit...that also means cleaning the TB and IDC. As noted before, I also replaced the DISA valve with a Dr. Vanos unit.
29914

I also changed the oil with Mobil 1 & a Mann Filter. It was missing the Oil Drain Plug access Panel, so replaced that...(nothing fun to see here). Next was the Vanos work - new seals and the rattle repair kit (and a new Vanos Oil Line and the new banjo bolts to boot). This was a first, so I didn't know what to expect...I made sure I read over the instructions on the GAS site, and things went well...I didn't have to sand down the new rings or the washer...good pre-load on the bearing but it spun/no binding...buttoned that up and of course had to replace the VCG & all those small rings that go along with it. Whew...lots of work under the bonnet! I was relieved when I hooked up the New OE battery and she started up no problem with no lights:fistpump

My windshield cowl was bad...first time on this job and getting the darn windshield wipers off the car is a major PIA! I later picked up a tool that removes them...much easier!...Check out how much shizzz was under the cowl!29915
And of course cleaned her up:29916

I also went ahead and replaced the Cabin Air filter and a disintegrating pressure hose from the air pump to the solenoid valve and she needed a new Trunk emblem!

I'll wrap this update up with the Transmission fluid flush (Red Line D2 ATF) and the Differential fluid flush (Red Line MT-90 75W90)
29917

I still have to document my detail, and my caliper rebuild journey, but I'll save some fun for another day...

BMWCurves

05-11-2017, 12:28 PM

Damn, lots of stuff, nice work!

ZHPizza

05-11-2017, 12:41 PM

Fort Mill I hear ya! Strong work

holyc0w

05-11-2017, 01:09 PM

I need to do my windshield cowl as well. What's the tool for the wiper removal? Any other issues to note?

nextelbuddy

05-11-2017, 01:10 PM

I'd have to agree with BP...I've found the FCP site to be good, but not as user friendly as ECS, which I feel is polished. I'd also like to see more Kits/packages offered from FCP, which I've found to be convenient (and $$ saving) in the past when using ECS. IMO, the pros on FCP outweigh these minor things though. Further, the last couple times I ordered from ECS, the packaging was crap (little/poor use of paper/bubble)...

do you all not eve ruse www.getbmwparts.com ??

they are usually a few pennies to few dollars cheaper than FCP though they dont offer the warranty. They do have immediate access to the 2 guys via AIM so you can get an update very quickly on stock or how long it will take to order.

anandoc

05-11-2017, 01:38 PM

Thats great werk OP!

Oli77

05-11-2017, 02:48 PM

I need to do my windshield cowl as well. What's the tool for the wiper removal? Any other issues to note?

No tool, remove nut, and push down on the arm about 3 inches fron where the nut was.

Great job I! You are ahead of me on my ZSP.

///Mvious

05-12-2017, 09:52 AM

Damn, lots of stuff, nice work!

Thanks!

Fort Mill I hear ya! Strong work

I actually moved about a year and a half ago out near Lake Wylie...I need to update the profile

I need to do my windshield cowl as well. What's the tool for the wiper removal? Any other issues to note?

I used this (the second time I took them off...I didn't have them positioned correctly the first go) and it was waaaaay easier: https://www.ecstuning.com/b-schwaben-parts/schwaben-heavy-duty-wiper-arm-puller/018544sch01a/

I watched a couple guys pry them up, and though I was able to do it eventually (with no damage to the car) it was a B!tch!

do you all not eve ruse www.getbmwparts.com ??

they are usually a few pennies to few dollars cheaper than FCP though they dont offer the warranty. They do have immediate access to the 2 guys via AIM so you can get an update very quickly on stock or how long it will take to order.

I have in the past and I like them...I just get in a habit of using my go-to's...I've really grown to like FCP though so I tend to go there now with little price shopping

Thats great werk OP!
Thank you sir!

No tool, remove nut, and push down on the arm about 3 inches fron where the nut was.

Great job I! You are ahead of me on my ZSP.

My technique was to wiggle/pull & push on the arm with a good bit of force...it was like this piece and the wiper arm were fused together. Maybe this focused push 3 inches out is the key! holyc0w - try that first...The tool isn't that expensive though and you can find one cheaper than I linked above...the hardware that keeps it on and in place works against you after you remove the nuts...here is what it looks like:
29921