ATL ZHP - A TiAg Owner's Chronicle

[zj96sc]

Hello all!!

You may have seen me trolling the for sale forum for the last few weeks.

My previous BMWs include an Estoril on Dove E36M (no pics)

an Arctic on Black E36M:

http://i81.photobucket.com/albums/j234/paulkeith/cars/m3/Img_0885.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/m3/Img_0999.jpg

And a Lachsilber on Black E30 325is:

http://i81.photobucket.com/albums/j234/paulkeith/cars/e30/sale/DSC_0908Medium.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/e30/sale/DSC_0913Medium.jpg

After a LONG hunt, I've finally made it to ranks of ZHP ownership. Check out the created date on my AutoTrader saved search:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/autotrader_search.jpg

I was pretty set on a SilverGray, but Jason posted his Titanium Silver 04 for sale here on ZHP Mafia on June 26th. The car had an immaculately maintained history with full records, was a one owner, and looked to be in phenomenal shape. These pros were enough to sway me to a TiAg and I went for it.

Basics on the car:
2004 ZHP
Titanium Silver
Alcanatara, Black Cube, Sunroof, Cold Wx, Sirius, Bi-Xenons, HomeLink, HK
110,000 miles, Maintained with Old-School MX
Bone stock
Full records for all MX, window sticker too

Jason’s FS pics:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/frontquarterpassenger.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/interiorpassenger.jpg

Flew up last Thursday night and met Jason Friday morning. We exchanged funds for title and went to the DMV. Jason was a good enough guy to stick around with me at the DMV for 2 hours to get the whole transaction completed. A set of temp tags and $20 to uncle Connecticut, I was on my way back to Atlanta.

I overnighted in Waynesboro, VA. Some of you may know; this is the city just to the west of the start of the Blue Ridge Parkway. I got up at 5:45 Saturday morning, ate my "buffet" breakfast and was on the Parkway by 6:30AM. What did this mean? Ghost town. Oh, and fog. A lot. Of. Fog.

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/DSC_0405Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/DSC_0429Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/DSC_0417Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/DSC_0408Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/DSC_0424Large.jpg

Mile Marker 60 (I got on at MM0):

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/DSC_0433Large.jpg

Cruised the Parkway for 60 miles. Saw 4 other cars (all going the other direction), 5 deer, a turkey, and 8 cyclists….and that’s literally it. Perhaps not as much a “Driver’s” road as I expected, but simply stunning nevertheless. Glad I added it to the trip. Got back on 81 on the other side of Glasgow VA and made my way to Atlanta…with a quick stop at the Zentrum. :biggrin :

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/DSC_0436Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/DSC_0446Large.jpg

All in all, put exactly 1,000 miles on the car. Clicked over 1,000 literally as I pulled into my subdivision. The car was a blast. So smooth, quiet, strong, nimble; basically a fantastic cocktail of sport blended with lux. This is what I read about the ZHP, what made me dead set on owning one, and I’m glad it has turned out to be true.

I’d like this thread to serve as a logbook for my work on the car, including maintenance, mild mods, and hopefully give some experience back to the ZHP Mafia community. I’m a pretty handy DIYer and hopefully I can document my work well enough to give some knowledge back this forum that has already helped me a great deal.

To start off the repairs and mods (a very quick and dirty bit on each):

Idle Stumble: The car developed a slight stumble when revving off of idle in the last 20 or 30 miles of the trip. Ambient temps were in the high 90s with humidity in the 80s and the car had been heat soaked for hours – not that this should ever matter. I replaced the very dirty and grimy K&N filter with a paper Purolator (for now) and used MAF cleaner on the MAF. So far so good. Will likely stick with paper but move to a Mahle when I get a chance to place my first big Pelican Parts order.

Aux Input: Bought BMW’s aux input. Took me maybe 15 minutes to install. Pop the glovebox trim off (with plastic trim tool to avoid marring), then the radio trim. 2 Phillip’s screws, pop the radio out. Remove the connector at the rear, slide out the blue retaining clip, and add the aux input connector. Route the cable to the spot of your choice; I went with the upper right corner of the middle console bin. Still need to pick up a 3.5mm M/M cord. Once connected, the radio automatically adds the source to your “Mode” list; I now have AM/FM, Disc, Disc Changer, Sirius, AUX.

Shift Knob: Replaced the worn original knob with another OEM ZHP knob. What else? This is the best knob on the market, bar none. Am considering a rebuild of the linkage; it’s a bit sloppy.

Posts/work to come soon:
Lighting: Original ZKW 2003 build year driver’s Xenon has zero light output. It turns on, but looks like a cataract. Replacement OEM ZKW 2005 build year Pax light has orange glow at periphery of output pattern. Suspected & confirmed severely burned bowls on both. Hopefully this is the extent of the problem. Solution has shipped, I will document all my work and post it up here.

Exterior Trim: Ordered replacement front bumper center moulding. GA requires no front plate; I ordered a plain and also a Euro plate strip. I was born in Germany and spent several years of my life living there, so I might rock a German plate as a bit of a throwback. Can’t decide if I want a Munich plate as homage to BMW, or perhaps my family’s hometown as something more personal. I’m going to go with the plain center moulding until I make up my mind.

Exterior Trim: Ordered Khoalty black kidneys. The original chrome kidneys are cracked and barely hanging on. Going to try the flat black look.

MX: Expansion tank, belts, idlers ASAP. Rest as per OSM.


Also got a new BMWCCA membership and joined the ZHPMafia SIG too.

Anyway, sorry for the marathon! Hope yall enjoy - I’m looking forward to getting to know everyone around here better.

-Paul

[Marcus-SanDiego]

Congrats on the purchase. Looking forward to reading more about your car.

[danewilson77]

Congrats!

HTC Thunderbolt+TT

[mimalmo]

Nice writeup Paul!

[kayger12]

Great read. Thanks!

[Mtnman]

Excellent. Cant wait to read more...and if you took the parkway the whole way, you came right by me!

[Alphatek45]

Great stuff, Paul. We are one step closer to a Georgia meet!

[static667]

Congrats on the car! Those are some great pics on the parkway. I like the one with the clouds in the valley... :drool

[zj96sc]

Thanks all for the kind words. Alphatek....we're not too far apart. How many other local members are there?

This afternoon I picked up a handful of detail products. I've tried a couple different products here and there with the Ms and 325, so I picked and chose and also took some recommendations from paint correction threads here and on E46F.

What I picked up today from AutoGeek and Detailer's Domain:

Hands off first rinse:
Autogeek's Quart Foammaster Foam Gun
DP Xtreme Foam Formula Auto Shampoo

Hands on second wash:
lambswool mitt
P21S Bodywork Conditioning Shampoo

Wheels:
SONAX Wheel Cleaner
Daytona Speed Master Wheel Brush
Clean Wheel Lug Nut Brush

Drying:
P21S Drying Towel

Interior:
Carrand 2 in 1 Electrostatic Detail Brush
303 (what else)

Engine compartment:
Adam's All Purpose
Couple brushes

Glass:
Stoner's

Plus a few microfibers, towels, etc.

As far as polishes/sealants/glazes/waxes go, haven't made up my mind yet. I'm leaning towards Klasse AIO, Klasse Glaze, and P21S Carnuba as a final step. Used zymol, mothers, and meguiars products in the past and never really had any complaints. This paint is in pretty good shape for my standards and uses (and was maintained yearly with Klasse) so Klasse and P21S should probably do the trick for at least some time.

[zj96sc]

Few questions for the masses...

- My driver's window makes a screeching noise when you first move it off the seals, maybe the first 1/4" of travel. Sounds like if you dragged your hand on a clean sheet of glass kind of screeching noise. Rest is smooth quick and silent. Is there a way to "lube" window seals in a way that won't get on the glass itself?

- Tint. I want to tint the car badly. In the south it is a must-have, but I'm worried about a good job on the dot matrix. There is a Very highly recommended local guy right by work that uses F1 film. I'm leaning towards 35% film all around. Thoughts? Cautions?

[danewilson77]

Damn, I like those seats.

Sit in them sometime.

It's like having your butt cheeks caressed by.....well....your significant other...

HTC Thunderbolt+TT

[static667]

Alcantara...:drool

[zj96sc]

Thinking about trying Carbaflo on my squeaky driver's window seals. Spec sheet for the stuff said it eliminates "window judder" so I think it might be the right stuff. Invisible and odorless. A bit pricey though, but most folks say the stuff works wonders and the bottle lasts a long time. This stuff replaced BMW's gummipflege for all seal and rubber noise issues. Supposed to be used in conjunction with a silicone remover if you've used gummipflege in the past. Found out about it by reading through previous mx records from the seller.

Carbaflo KSP105. BMW P/N 83230309627, $38.78.

[05ZIPPYZHP]

Always nice to see a fellow Georgian styling a ZHP. Nice thread, looking forward to seeing it progress and if you can find out a fix to that squeak, have an M that does the same thing.

[zj96sc]

Not bad, so that's that...3 of us in the ATL area now?

Putting together the list for my maintenance baseline order.

Plans for now, at 110k:
Belts
Idlers
Tensioners
Upper + Lower Rad Hoses
Expansion Tank
Air+Fuel+Cabin Filters
Shifter Bushing + Washers + Circlips (going to try to tighten up the stock assembly until I get around to a real SSK)

Then in about 6,000 miles I'm due for an oil change.

At 120k or so I'll do a full Inspection II, maybe skipping the oil until about 123k or so.

What am I missing?

Got 5 packages arriving in the next 3 days from Tischer, Khoalty, EBay, AutoGeek, and Detailer's Domain. Should have lots of eye candy and updates :biggrin

[zj96sc]

Big update!

So I pulled both headlights apart. I found both xenon bulbs to be quite cloudy, driver’s being the worst:

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0404Large.jpg

I also found that my driver’s bowl was indeed burned (right) but the passenger bowl was actually still in perfect shape (for now anyway):

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0425Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0405Large.jpg



I did a lot of reading on all of the possible solutions, including just putting new ZKW bowls back in, swapping to AL assemblies and buying the 3-wire bixenon controllers, doing a lightwerkz retrofit, on and on, and finally stumbled across a guy on E46F, member “fgin,” who claimed that E90 projectors were a 90% plug and play kind of swap, minimal drilling, no JB welding, etc. ZKW got their head out of the sand and made the e90 bowls out of metal. They also use an identical in function and design bixenon solenoid with connectors that accept the E46 wiring. E90 projectors pop up on ebay for about $30 without bulbs, so this sounded like it was worth a shot. Ordered two for $70 shipped.

How they arrive (along with my headlight and the tools I needed):

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0401Large.jpg

First you have to unbolt the adaptive lightning motor:

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0411Large.jpg

Then drive the adaptive lighting hinge pins out with a long thin screwdriver + hammer:

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0413Large.jpg

Unscrew the two screws holding the bixenon shutter on, then use a thin screwdriver to separate the bixenon shutter from the bixenon shutter solenoid actuator pin:

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0415Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0419Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0420Large.jpg

Using a thin screwdriver, lift the retaining tab on both sides of the bixenon solenoid, and slide it off of its tracks:

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0421Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0422Large.jpg

Remove the last 4 torx screws holding in the bowl:

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0423Large.jpg

Now you’re down to just the plastic frame, which is ready for you to modify as needed:

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0424Large.jpg

At this point, I’ll have to use some of fgin’s pics. I didn’t take pictures as I worked through driver’s side as I planned to do all the pictures on the passenger assembly. When I got my passenger OEM bowl out to find it wasn’t burned, I had already assembled the drivers’. So here are pics of where the plastic frame needs to be modified (3 holes drilled, adaptive arm cut off, few other trimmings), all credit to fgin on E46F (his link here: http://www.e46fanatics.com/forum/showthread.php?t=845704)

http://img96.imageshack.us/img96/6154/modsl.jpg

Once you’ve completed those mods, the basket will hold the bowl and attach to your projector lens perfectly. The only remaining issue is that the E90 projectors use D1S bulbs whereas E46s use D2S bulbs. To remedy this issue, you have to modify the bulb holder (piece of bent wire). The bulb sits in the socket fine. Fgin’s design used some screws which I didn’t like. I wanted it to be 100% removable by hand. I spent a solid 1.5 to 2 hours farting around with this wire, but eventually bent up a shape that retained the D2S bulb in the D1S socket very solidly (let's see if someone can spot the cap from the medicine i needed to stay calm while bending this stupid wire) :

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0409Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0408Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0407Large.jpg

Reassemble all and here is the pattern you get:

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0433Large.jpg

Note that the mirror smooth reflector design of the e90 (driver’s) has a much smoother light output pattern from the center of the output down whereas the angled reflector bowl of the e46 ZKW (passenger) produces noticeable patterns in the light below center. They’re not a 100% match, but I don’t care. These are like daylight compared to what I had before.

I actually realized when my passenger headlight was out that the bixenon solenoid was pretty rough in movement and feeling, so I replaced it with the smooth feeling unit from my now-junk driver’s bowl.

I’ve filled both lights with 4300K replacement bulbs from Khoalty. I plan to order some Philips 4300K at some point as the bulbs from Khoalty are no-name Chinese bulbs, I question their reliability and don’t want it as an asterisk in my head down the line. I also spent a good bit of time polishing both the bowls and lenses with a microfiber. Both shined up quite a bit, the lenses especially were just plain dirty.

So there you go. For $70 for two E90 projector assys, and about 3 hours of fiddling with drill bits, torx drivers, and pliers, you can remedy the ZKW bowl flaw permanently with all OEM parts, retain bixenons, no JB weld and no codes. Do it.

Paul

[zj96sc]

I bought black kidney grills from Khoalty as the stock kidneys were cracked and rattling.

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0431Large.jpg

I also bought the OEM bumper trim filler to replace the front plate bracket. I picked up the euro plate bracket as well so I can run a plate when I figure out what I want to get.

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0397Large.jpg

Before:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0398Large.jpg

Plate filler (before cleaning dirt off bumper):

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0399Large.jpg

Black kidneys:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0432Large.jpg

Very happy with the cosmetic improvement of the front end.

[zj96sc]

I put the entire mx history plus all paperwork for the ZHP into protective sleeves in a 3 ring binder:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0428Large.jpg

My hardback bentley (didn't realize it was a hardback as i ordered it....woops):

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0429Large.jpg

Mad goodies:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0430Large.jpg

Sonax at work:
http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0440Large.jpg

First attempt at a foam gun ever, still messing with the settings. For $59 it's tough to beat:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0438Large.jpg

Soaked with Adam's All Purpose and agitated with a brush:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0441Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0443Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0448Large.jpg

Rinsed (and underhood insulation removed to dry, check out the discolored spot):

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0445Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0446Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0447Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0449Large.jpg

Followed this all with a handwash with lambswool and P21S. Dried with an Absorber.

All done:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0450Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0451Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0454Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/HeadlightsTrimKidneysCleanup/IMG_0455Large.jpg

The astute will note that my passenger headlight is out in this picture. that's because, I, in my infinite wisdom, left the rear dustcover off my headlight when I reinstalled in. Washing the engine compartment got a ton of water in there. DOH! I took it back out and set it in the sun to dry before I fire it back up.

By the way, Adam's All Purpose ROCKS. One of the best car products I've used in a long time. Many thanks to Detailer's Domain for posting its effectiveness here on ZHP Mafia and the link to purchase it. I'll be back for more, that's for sure.

Anyway, there's my slew of updates. Enjoy the pics, ask questions, leave comments.

Later!
Paul

[Marcus-SanDiego]

Paul, your car looks great.

[05ZIPPYZHP]

Can't help but appreciate a fellow DIY'er. The progress looks superb. Feel free to review the foam gun, I've been debating on purchasing one. Just need justification for the price tag.

[Alphatek45]

Can't help but appreciate a fellow DIY'er. The progress looks superb. Feel free to review the foam gun, I've been debating on purchasing one. Just need justification for the price tag.
+1

[zj96sc]

I've never used a foam gun before, so I can't really say how this one did or didn't measure up. It was easy to use, covered the car in foam, but it wasn't quite what I had seen on detailing threads as far as a thick white foam layer coating the car. What I pictured is about as good as it got. I never messed with any of the product/water ratio settings though so the devil may be in the details there. I'd be though that this is probably because this is a $59 foam gun running on ~50psi tap pressure instead of a $2-300 foam gun running on a pressurewasher.

For my uses, this thing will work great. It gets a majority of the large stuff off the paint before I come through with the lambswool, which is all I wanted out of it.

I got the smallest canister: http://www.autogeek.net/foam-gun.html

[05ZIPPYZHP]

Thanks for such a fast response. I have been looking at a foam gun for some time after seeing their use in the detailing section on here. Will have to look into it even more. Looking forward to seeing more progress as well, keep up the good job!

[fricker66]

Great thread. Will certainly be following your updates.

[zj96sc]

So...now that most of the immediate issues have been addressed, I got one last bit order put in. This should have me set until 120 or 125k when I do an inspection II

- Upper & Lower Hoses
- Expansion Tank
- Air Filter x2
- Oil Filter x2
- Fuel Filter
- Activated Carbon Cabin Filter
- 14 QTs 5W30 BMW Synth
- 2 Gal BMW Antifreeze
- Hydraulic Tensioner
- Water/PS/Alt Belt
- Tensioner Pulley
- Idler Pulley
- A/C Belt
- Wiper Blade Refills
- Valve cover bolt trim caps
- New stud + washer + nut for 1 valve cover bolt that I found cross threaded

She has been bleeding my wallet hard since purchase but this should actually be the majority of the stuff I need to get the maintenance history established and most of the common failure points addressed. Should be (knock on wood) smooth sailing after this for a while.

[Alphatek45]

I like your style,sir.

[Hermes]

Very nice car bro, I just have to say you are def. doing it right with your maint/mods for I guess you can say retrofitting your car. I wish I put that much effort when I first bought mine but I guess I got around to it eventually.

[zj96sc]

Ah, as if it heard me, I spoke too soon.

On the list above, I forgot to add a shift bushing, new washers, and circlips. I hope I can tighten up the stock assembly a little. I actually have play in line with the shift rod (up and down relative to the tranny tunnel) so I hope the new bushing eliminates that.

On my way into the garage this morning I ran my finger along the paint to see what Saturday's results were and I was not happy with the feeling. I also wasn't really getting any beading when I washed it - it was time. So I came back in, ate my words, and placed two more orders of products.

Detailers Domain:
-1 Gal Adam's All Purpose (may or may not have already depleted my small bottle :biggrin)
-Uber "FINE" Blue Clay Bar Kit

AutoGeek:
- Klasse AIO
- Klasse Glaze
- P21S Concours Look
- Microfiber and Foam Applicators
- Microfiber Buffing Towels

So.......THIS should do it. Or that's what I'll tell myself.

Plan will be to wash, clay, wash, AIO, buff, Glaze, wait 12 hours, buff, P21S, buff, P21S, buff. Should have it well protected for ~6 months and sexy-shiny for ~6 weeks.

[zj96sc]

- Upper & Lower Hoses
- Expansion Tank
- Air Filter x2
- Oil Filter x2
- Fuel Filter
- Activated Carbon Cabin Filter
- 14 QTs 5W30 BMW Synth
- 2 Gal BMW Antifreeze
- Hydraulic Tensioner
- Water/PS/Alt Belt
- Tensioner Pulley
- Idler Pulley
- A/C Belt
- Wiper Blade Refills
- Valve cover bolt trim caps
- New stud + washer + nut for 1 valve cover bolt that I found cross threaded


Here’s what that all looks like, plus the detailing products:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/110k_Maintenance/IMG_0456Large.jpg

My crossthreaded and snapped valve cover stud:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/110k_Maintenance/IMG_0458Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/110k_Maintenance/IMG_0461Large.jpg

All the new parts (washer, rubber retainer, bolt:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/110k_Maintenance/IMG_0459Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/110k_Maintenance/IMG_0460Large.jpg

Stud in:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/110k_Maintenance/IMG_0463Large.jpg

Done:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/110k_Maintenance/IMG_0464Large.jpg

Simple stuff. Just cleaning up someone else’s durp.

Front all apart (air intake ducting off, fan out):

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/110k_Maintenance/IMG_0465Large.jpg

Scrubbed tensioner bracket plus new hydraulic tensioner:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/110k_Maintenance/IMG_0466Large.jpg

Installed:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/110k_Maintenance/IMG_0469Large.jpg

New tensioner pulley against old:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/110k_Maintenance/IMG_0470Large.jpg

Belts on:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/110k_Maintenance/IMG_0471Large.jpg

New tank in:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/110k_Maintenance/IMG_0475Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/110k_Maintenance/IMG_0477Large.jpg

New cabin filter against old:

http://i81.photobucket.com/albums/j234/paulkeith/cars/ZHP/110k_Maintenance/IMG_0480Large.jpg

There you go. Not much tech or DIY here, just some pics of what I got done. I didn’t get any pics of the disassembly, it was pretty dirty and I was kind of ‘in the zone.’

Any questions, post up.

Paul

[Alphatek45]

Great stuff, Paul. Love when my garage looks like pic # 1.

[danewilson77]

Thanks for the pics Paul. Pics are always welcome. The more...the better.

HTC Thunderbolt+TT

[lilcdkey]

Great read. OEM clears next :)

[zj96sc]

Nah. I don't do clears. My two E36s had clears and I put OEM ambers back on. My E30 came with blackouts and I put OEM ambers back on. This one is gonna stay amber. Guess that's just how i roll :biggrin

[jayjay_dee]

you are definitely doing a great job on your car... thats why im subscribing to this thread, i wanna see/read all your updates...

we have almost identitical car, except mine is 2005, automatic...

keep up the good work!!!

[zj96sc]

Car went totally haywire this morning. Not a good situation.

My symptoms:

1. No instrument cluster blinker lights (but blinkers work outside)
2. No instrument cluster fog light indicator (but fogs work)
3. No dash/interior illumination dimming
4. No 'key in ignition' or 'lights on' buzzer when door is open
5. No keyless entry (central locking works with key in door)
6. Had wipers in the intermittent setting and they started to move with no rain (randomly while sitting at a red light)

Interestingly, the problem would change when I hit bumps..IE, dash dimming would catch up with the position of the dimmer wheel, blinker indicators would fire up if the blinker was on while I hit the bump, fog light indicator would click on if the fogs where on when I hit the bump, etc. After I parked at work and was trying to diagnose further, I closed a door and the interior buzzer started buzzing with the driver door open, but no key in or no lights on...so something with impact to the chassis seems to be affecting the problem.

Found a thread over on e46. Identical symptoms, sounds like a k-bus problem. either a bad module somewhere on the k-bus or a shorted wire on the k-bus. going to have to isolate tonight.

http://forum.e46fanatics.com/showthread.php?t=677160&highlight=lots+of+electrical+issues

When I had this car PPI'ed, it came back with a "GM internal fault." At that time I emailed the guy that runs BMWGM5, he said he sees this error every now and then and it rarely causes a problem. I think maybe this is this issue manifesting itself.

I'll keep the mafia posted.

[zj96sc]

Followed the troubleshooting procedure in the above thread and traced it, of all places, to my radio. Guess something is up with it's k-bus communication ability.

So....guess i'll research the swap to another business CD. I've never seen an aftermarket radio install in an E46 that didn't look like crap.

[ranger]

I had a situation like that with my 2005 BMW 325i sedan and it was a dying battery. Good luck - hate electrical issues. Surely there are some Electrical Engineers at Lockheed!

[zj96sc]

I have unfortunately lost this car due to a collision. No injuries on either side. My first and only traffic collision in 13 years and 250,000 miles. A shame but in the end everyone is healthy and that’s what insurance is for.

I thought long and hard about even posting this online at all as I do not feel it is wise to do so, but decided to do it only to share what I learned about valuation of the ZHP package in the eyes of insurance companies as I feel this will be relevant information to anyone on this forum.

My insurance used a major third party auto collision valuation service to determine the value. The values they provide are retail values. This firm felt that a 2004 ZHP 6MT, 112k, alcantara, cold wx, xenons, heated seats, sirius in noted “excellent” cosmetic and mechanical condition was worth $12,000. $12000 RETAIL.

This is $3000 lower than KBB and NADA retail for the same car and falls in just over KBB private party good.

I pushed back and provided the 11 or so 6MT sedans on autotrader right now with an average price of $15,339. They countered that the valuation included comparison to 44 comparable vehicles for sale and in each case "correction factors" had been applied to adjust for mileage, options, and condition. The fundamental problem here is that the ZHP is only a +$x option to a normal 330i/ci in their eyes and not a truly separate car like we think it is. Beyond that, a ZHP is not identifiable by year/make/model or VIN, and as a result is very hard for a valuation firm to understand or identify in comps. BMW would've been smart to establish the ZHP as its entirely own trim package given its $3900 price tag to help owners out in the future, but unfortunately they didn't so it will fall into a comp category filled with high mileage auto tranny non-sport 330is. To a corporate bean counter, this car is nothing.

I offer this as fair warning to those of you out there operating ZHPs – in all likelihood, your ZHP is drastically underinsured (to the tune of 20-30%) for what you believe it is worth and what it would cost you to replace like with like. This was made particularly poignant in my case due to the brevity of my ownership; however it could spell serious financial trouble for many of you out there if you found yourself in a total loss situation, particularly those of you highly leveraged with debt on the car. I also would caution prospective buyers to keep your wits about you and do not overpay for the package beyond what you’d be comfortable losing, as in all likelihood this is exactly what will happen in such a situation.

I’m beginning to waver on my desire to purchase another ZHP at all for this reason…unless they all start selling a KBB private party good. I just can’t justify driving at the non-trivial financial risk that this valuation gap poses.

Good day to everyone out there in the Mafia….keep your head on a swivel and your SA hyperactive.

-Paul

[Marcus-SanDiego]

Paul, thanks for the information. My guess is that, when we get insured, we need to educate the insurance company and "over" insure?

[danewilson77]

Great data. Sorry to hear of your loss. This is why I definetely am a supporter of TLP.

[zj96sc]

As I see it, we've got probably 4 options:

1 - ensure you purchase at an extremely competitive price, somewhere in the neighborhood of KBB private party fair to good, for a well maintained car. If the car requires maintenance, adjust price accordingly such that your fully invested price to get the car to "retail" mechanical condition falls near KBB fair/good.

2 - when obtaining an insurance quote, have the insurer provide the "actual cash value" or "fair market value" that they're insuring the car for, or ensure that you're obtaining a full "replacement value" policy. If the values to not agree at that time, adjust accordingly with the corresponding increase in premium, if the company will even do this for you. a corollary here, as dane mentioned, is to definitely obtain a GAP plan in the case that you're heavily financed.

3 - accept moving forward and operating the car at some degree of financial risk

4 - choose not to own a ZHP

The 1st option is largely within our control and just requires you to be diligent in your search...and is probably good advice in the first place.

The 2nd option is something that never really dawned on me to ever do, but given this experience I feel that this may be quite critical for the ZHP.

The 3rd option is probably not the end of the world as the chances of this situation affecting most of us are relatively low in the grand scheme of things.

The 4th option is just heresy. :biggrin

[Marcus-SanDiego]

I know the E30 M3 guys had similar issues as their cars were going up in value. Insurance companies were not friendly.

Any E30 M3 owners have a story to tell? Any helpful hints?

Good work, Paul.

[95m3ltw]

I went through this when my E36 M3 LTW was totaled. State Farm offered blue book for a 95 M3 which was something like $20k at the time. I told the adjuster I would be sending 10 ads for LTW's and a bit of information for him to educate himself to the differences between normal M3s and LTWs. I also scanned the window sticker showing the $15k difference in price. Next day they raised the offer to $32k which I thought was more than fair.

With a ZHP, it might be a tad difficult justifying the difference since it is only a option package and not a model. While I dont know the legal side of things, I have found when push comes to shove, they typically pay the book value. I've known individuals who have gotten a few thousand more based on proof of condition and service records etc. Squeaky wheel gets the grease kind of thing.

[zj96sc]

updated photo links for e90 bowl retrofit as requested.


Big update!

So I pulled both headlights apart. I found both xenon bulbs to be quite cloudy, driver’s being the worst:

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0404Large.jpg

I also found that my driver’s bowl was indeed burned (right) but the passenger bowl was actually still in perfect shape (for now anyway):

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0425Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0405Large.jpg



I did a lot of reading on all of the possible solutions, including just putting new ZKW bowls back in, swapping to AL assemblies and buying the 3-wire bixenon controllers, doing a lightwerkz retrofit, on and on, and finally stumbled across a guy on E46F, member “fgin,” who claimed that E90 projectors were a 90% plug and play kind of swap, minimal drilling, no JB welding, etc. ZKW got their head out of the sand and made the e90 bowls out of metal. They also use an identical in function and design bixenon solenoid with connectors that accept the E46 wiring. E90 projectors pop up on ebay for about $30 without bulbs, so this sounded like it was worth a shot. Ordered two for $70 shipped.

How they arrive (along with my headlight and the tools I needed):

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0401Large.jpg

First you have to unbolt the adaptive lightning motor:

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0411Large.jpg

Then drive the adaptive lighting hinge pins out with a long thin screwdriver + hammer:

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0413Large.jpg

Unscrew the two screws holding the bixenon shutter on, then use a thin screwdriver to separate the bixenon shutter from the bixenon shutter solenoid actuator pin:

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0415Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0419Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0420Large.jpg

Using a thin screwdriver, lift the retaining tab on both sides of the bixenon solenoid, and slide it off of its tracks:

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0421Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0422Large.jpg

Remove the last 4 torx screws holding in the bowl:

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0423Large.jpg

Now you’re down to just the plastic frame, which is ready for you to modify as needed:

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0424Large.jpg

At this point, I’ll have to use some of fgin’s pics. I didn’t take pictures as I worked through driver’s side as I planned to do all the pictures on the passenger assembly. When I got my passenger OEM bowl out to find it wasn’t burned, I had already assembled the drivers’. So here are pics of where the plastic frame needs to be modified (3 holes drilled, adaptive arm cut off, few other trimmings), all credit to fgin on E46F (his link here: http://www.e46fanatics.com/forum/showthread.php?t=845704)

http://img96.imageshack.us/img96/6154/modsl.jpg

Once you’ve completed those mods, the basket will hold the bowl and attach to your projector lens perfectly. The only remaining issue is that the E90 projectors use D1S bulbs whereas E46s use D2S bulbs. To remedy this issue, you have to modify the bulb holder (piece of bent wire). The bulb sits in the socket fine. Fgin’s design used some screws which I didn’t like. I wanted it to be 100% removable by hand. I spent a solid 1.5 to 2 hours farting around with this wire, but eventually bent up a shape that retained the D2S bulb in the D1S socket very solidly (let's see if someone can spot the cap from the medicine i needed to stay calm while bending this stupid wire) :

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0409Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0408Large.jpg

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0407Large.jpg

Reassemble all and here is the pattern you get:

http://i81.photobucket.com/albums/j234/paulkeith/cars/TIAG_ZHP/HeadlightsTrimKidneysCleanup/IMG_0433Large.jpg

Note that the mirror smooth reflector design of the e90 (driver’s) has a much smoother light output pattern from the center of the output down whereas the angled reflector bowl of the e46 ZKW (passenger) produces noticeable patterns in the light below center. They’re not a 100% match, but I don’t care. These are like daylight compared to what I had before.

I actually realized when my passenger headlight was out that the bixenon solenoid was pretty rough in movement and feeling, so I replaced it with the smooth feeling unit from my now-junk driver’s bowl.

I’ve filled both lights with 4300K replacement bulbs from Khoalty. I plan to order some Philips 4300K at some point as the bulbs from Khoalty are no-name Chinese bulbs, I question their reliability and don’t want it as an asterisk in my head down the line. I also spent a good bit of time polishing both the bowls and lenses with a microfiber. Both shined up quite a bit, the lenses especially were just plain dirty.

So there you go. For $70 for two E90 projector assys, and about 3 hours of fiddling with drill bits, torx drivers, and pliers, you can remedy the ZKW bowl flaw permanently with all OEM parts, retain bixenons, no JB weld and no codes. Do it.

Paul