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Thread: BMW E46 ZHP DIY and Preventative maintenance doityourself

  1. #1
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    BMW E46 ZHP DIY and Preventative maintenance doityourself

    I just wanted to save this somewhere. It's a work in progress.

    M54


    M54






    S54 broken down


    The wiki does a fairly good job at laying out the problem area's....

    http://www.bimmerfest.com/wiki/index...ook_out_for.3F

    Additionally....

    Please read this thread prior to procedding to work on your car. Ask if you have questions about properly supporting car.

    http://www.zhpmafia.com/forums/showt...hard-Klorczyk)

    1. Keep up with Service I and service II inspections. Early preventative maintenance is key at maintaining longevity.

    http://www.linquist.net/motorsports/bmw/service

    2. Change oil with BMW LL-01 approved oil every 7000-9000 miles. Intake filter and in cabin air filter every 15000 miles.

    FYI...WIX oil filters are not OE/OEM and one should go with Mahle or Mann...easy to find, too.

    http://www.bmwusa.com/Standard/Conte...ngineOils.aspx

    http://www.dvatp.com/bmw/diy/oil_service/









    3. Suspensions on E46 seem ok for the first 100,000 miles...but after that most swap out, due to suspension getting tired and fatigued. This also depends on driving style and whether or not you're lowered. Additionally make sure your tires and alignments are up to stuff, as driveability is really affected by these two maintenance items.

    CONTROL ARM DIY = http://forum.e46fanatics.com/showthread.php?t=421918







    Control Arm Review by FCPGroton


    FCAB DIY
    http://www.zhpmafia.com/forums/showt...rm-Bushing-DIY

    http://www.zhpmafia.com/forums/showt...5-Coilover-Diy

    4. Brake pads/rotors seem good for the mild mannered driver out to 100,000 miles....but is solely dependant on driving style.



    http://www.dvatp.com/bmw/diy/brakes/

    5. FSR (Final stage resistor) for the blower motor seems to fail regularly. This will be indicated by blower motor acting erradically

    http://www.e46fanatics.com/forum/sho...d.php?t=713544



    6. Batteries last 5-7 years. A lot of info in post #27 and #28.



    http://www.zhpmafia.com/forums/showt...-BMW-E46/page3

    7. Tranny and diff fluid should be swapped no later than 100,000 miles as BMW re-defined "Lifetime" as 100,000 miles. After that...I think most recommend around 30,000 miles to be safe.

    Manual transmission fluid change
    http://www.impee.co.uk/transmission_fluid_change.htm

    Automatic transmission fluid change.
    http://forum.e46fanatics.com/showthread.php?t=438667

    8. Haven't heard of too many subframe issues with ZHP's but there was a class action lawsuit last year, and it seemed most affected were 99-02 E46's.

    http://forums.bimmerforums.com/forum....php?t=1248770

    VIDEO-POST 245
    http://forum.e46fanatics.com/showthr...me&page=13

    9. Lower intake boot developes tears/cracks due to design and high temperature's.

    http://www.zhpmafia.com/forums/showt...ISA-inspection



    10. ICV does become dirty and needs to be cleaned with carb cleaner. Inspect upper/lower intake boot, and inspect DISA when doing this.





    11. DISA valve failure due to design flaw.

    http://www.bimmerfest.com/forums/sho...d.php?t=323335

    11.5. DISA o-rings and DISA repair kit

    http://germanautosolutions.com/DISA_O-Rings.html

    http://www.germanautosolutions.com/D...epair_Kit.html



    The resonance system provides increased engine torque at low RPM, as well as additional power at high RPM. Both of these features are obtained by using a resonance flap (in the intake manifold) controlled by the ECM.

    During the low to mid range rpm, the resonance flap is closed (i.e., the flap is actuated by alternator voltage such that it is held vertically against spring tension). This produces a long/single intake tube for velocity, which increases engine torque.

    During mid range to high rpm, the resonance flap is open (i.e, the control voltage is reduced to zero which causes the flap to return to the horizontal rest position due to spring tension) . This allows the intake air to pull through both resonance tubes, providing the air volume necessary for additional power at the upper RPM range.

    When the flap is closed, this creates another "dynamic" effect. For example, as the intake air is flowing into cylinder #1, the intake valves will close. This creates a "roadblock" for the in rushing air. The air flow will stop and expand back (resonance wave back pulse) with the in rushing air to cylinder #5. The resonance "wave", along with the intake velocity, enhances cylinder filling.

    The ECM controls a (magnetic) solenoid valve for resonance flap activation. At speeds below 3750 RPM, the solenoid valve is energized (with alternator voltage at the harness connector) and vacuum supplied from an accumulator closes the resonance flap (where the vacuum accumulator is apparently a one-way flap valve with a 1/16" entrance hole in the side of the DISA) . This channels the intake air through one resonance tube, but increases the intake velocity.

    When the engine speed is greater than 4100 RPM (which varies slightly - temperature influenced), the solenoid is de-energized (i.e., the harness control signal goes from ~13.8 volts DC to zero volts DC) The resonance flap is sprung open (by spring tension), allowing flow through both resonance tubes, increasing volume.











    12. VANOS software replacement due to BMW using incorrect material for seals on VANOS pistons. (BUNA-N vice Viton)

    I would have 1qt of whatever oil you use, and permatex to go along with the below.

    NOTE: The easily broken parts....have never been broken by me...after 7 vanos jobs.

    I only get the RED items below when doing this job.

    ABSOLUTELY REQUIRED
    -Double vanos seals repair kit (6-cyl) (BS001) $60/each (www.beisansystems.com),
    -Vanos gasket (11-36-1-433-817) 6.73/each
    -2 x vanos oil hose/pipe washer (32-41-1-093-596) $.25/each

    OPTIONAL PARTS
    M52TU & M54:
    Valve cover gasket replacement parts:
    -Valve cover gasket set (< 09/02 11-12-9-070-990, >= 09/02 11-12-0-030-496) $34.26/each
    -15 x valve cover bolt grommet (11-12-1-437-395) $1.73/each, oil fill neck gasket (11-12-7-526-447) 2.29/each

    Easily breakable parts:
    -2 x vanos piston bolt (11-36-1-748-745) $1.42/each,
    -4 x engine cover bolt/nut cap (11-12-1-726-089) 3.27/each, (E39 2 x, E46 1 x)
    -Fan shroud rivet (17-11-1-712-963) $.27/each, E39:
    -Radiator overflow neck (17-11-0-419-132) $1.67/each
    -Easily lost parts: 4 x engine cover pad (11-12-1-730-352) $1.98/each

    M56:
    Valve cover gasket replacement parts:
    -Valve cover gasket set (11-12-7-521-009) $63.05/each & (11-12-7-521-010) $17.52/each,
    -15 x valve cover bolt grommet (11-12-1-437-395) $1.73/each
    Easily breakable parts:
    -2 x vanos piston bolt (11-36-1-748-745) $1.42/each,
    -Fan shroud rivet (17-11-1-712-963) $.27/each

    OPTIONAL AND/OR PERFORMED AS NEEDED:

    The anti rattle kit install will require the kit from beisansystems, an impact wrench, socket, and soft jaw vice liners, that can be procured through the beisan site.




    13. Do plugs when you do VANOS. usually good for around 100,000 miles. Only do coils if indicated by misfires and OBDII codes.




    14. CPS (Camshaft Position Sensor) failure seems pretty regular.

    http://forums.bimmerforums.com/forum....php?t=1209578

    15. Coolant system design flaws promote changeout prior to 100,000 miles (This includes Upper/lower radiator hose, T-Stat, Temp sensor, water pump, expansion tank, coolant)

    http://www.bmw330ci.net/maintenance/completecoolant.php

    16. Belts (2) and pullies (3) should be replaced prior to 100,000 miles.

    http://www.zhpmafia.com/forums/showt...Upgrade-Layout

    http://www.zhpmafia.com/forums/showt...ntine-Belt-Diy

    http://forum.e46fanatics.com/showthread.php?p=12396655



    17. E46 taillight ground issue. This will be indicated by a BOW for a short period of time, which can be cleared by turing lights on....then off.

    http://forums.bimmerforums.com/forum....php?t=1076114

    http://wwww.bimmerfest.com/forums/sh...d.php?t=437313

    http://www.zhpmafia.com/forums/showt...ght=tail+light

    18. Strut tower mushrooming can be avoided by purchasing re-enforcement plated from Turner, or by buying a strut bar.

    http://www.turnermotorsport.com/p-32...ates-pair.aspx

    19. Oil level sensor failure. I have heard of this issue many time. Indicated by Oil level light coming on after startup, then clearing approximately 1 minute later. Oil level will be steady during this.

    http://www.bokchoys.com/differential...vel_sensor.htm

    20. Pillar felt sag. This is a common issue. Replacement is pretty cheap...but even cheaper is the DIY.

    http://forums.bimmerforums.com/forum....php?t=1214885

    http://forums.bimmerforums.com/forum....php?t=1201923

    21. Power Steering flush and MAF sensor cleaning.

    http://www.linquist.net/motorsports/bmw/maf

    22. Power steering pump and reservoir replacement.

    http://www.zhpmafia.com/forums/showt...ir-Replacement

    23. CDV DELETE

    http://www.zeckhausen.com/CDV.htm

    24. Window Regulator. Failure is very common on E46.

    http://www.e46fanatics.com/forum/sho...d.php?t=356847

    25. Sunroof repair DIY

    http://www.lincomatic.com/e46sunroof/e46sunroof.html

    26. To find out what options your car came with, look at POST #1, below.

    http://www.zhpmafia.com/forums/showt...=email+germany

    27. Key Re-Initialization

    Get in and close all doors.
    Turn on the ignition and turn off quickly. (No more than 5 seconds) to start the process. Next action must take place within 30 seconds.
    Remove the 1st key.
    Hold the key up near your left shoulder (this is so it is closer to the remote reciever antenna - someone else suggested this).
    Hold down the unlock button (which is button 1 on my key) and press the lock button 3 times (center button on my key). Release the unlock button and the doors lock which confirms the operation.
    Quickly repeat steps 4 & 5 for key #2 etc.
    If it does not work, try doing the keys in opposite order. Key 2 then key1, vs 1 then 2.

    Remember to alternate your keys from time to time so that you keep the batteries in both charged. Some have found success with placing the key into a rechargeable toothbrush charger overnight as well.

    Another thing you can do is to replace the battery! It's not officially possible (or recommended) for the new key design (2000+) but it can be done.

    28. Resetting BMW Oil Service indicator.



    29. Tie-rod Replacement

    http://www.e46fanatics.com/forum/sho...d.php?t=779009

    30. E46 Instrument self test





    E46 Instrument Cluster Test

    31. Rear Shelf/Deck Rattle DIY

    HERMES STYLE
    http://www.zhpmafia.com/forums/showt...attle-Solution

    KAYGER12 STYLE
    http://www.zhpmafia.com/forums/showt...n-Kayger-Style

    32. CCV replacement - By Starless outta St. Louis, MO

    http://www.bimmerfest.com/forums/sho...d.php?t=417819

    33. Unlock and TEST your BMW E46 3 Series OBC Hidden Functions DIY



    34. Drug bin diy

    http://www.diymybmw.com/e46/drug-bin-cover/

    35. E46 Water Pump Cap

    http://www.understeer.com/onlinestore-engine.shtml






    36. E46 Fuel pump diagnosis and Filter replacement

    http://bimmerinfo.com/diy/fuel-filter/

    http://www.youtube.com/watch?v=aqVGpkan0rE


    37. E46 Transmission Mount Replacement

    http://m3.madrussian.net/diy_re_tranny_mnt.shtml

    38. E46 Engine Mount Replacement

    http://www.vorshlag.com/documents/in...nt_install.pdf

    Here are some good pics.....whist doing this on an ///M3.

    http://m3forum.net/m3forum/showthread.php?t=377846

    39. Automatic Transmission Information

    http://www.bmwmotorsports.org/BMW_docs/transfund1.pdf

    40. E46 M3 rear diff you will need the following.

    Rear subframe
    Diff housing
    M3 sway bar (M3 diff will hit your stock sway bar)
    M3 half shafts
    M3 drive shaft (are you 5 or 6 speed?)
    M3 abs sensors

    Basically I would go with Quaife at this point if it was me.

    Dont the steptronic ZHP have a 3.64 ratio? That is another option if you don't want to spend a ton.

    If you can source the right diff out of a ZHP auto or step and do the labor yourself you could do it for a couple hundred bucks. Don't be scared, diffs aren't hard until you start trying to set ring and pinion gears yourself. Which you don't have to do.

    Is a rear diff swap worth the money? IMHO one of the best damn mods you can do!!!" Cody Stevensen

    Vehicle speed = Engine RPM * Tire Diameter / (transmission gear ratio * diff ratio) --- convert any units as necessary.

    Solving for diff ratio, you get

    diff_ratio = RPM * circumference / (speed * trans_ratio) -- convert all

    So say you're at 3500 RPM in 4th gear (auto) when going 70

    diff_ratio = 3400 rev/min * 25pi inch/rev / (70mi/hr * 1056 (in*hr/min*mi) * 1)
    diff_ratio = 3.61



    41. Fuel Injector Servicing

    http://%3cbr%3ewww.bimmerfest.com/fo...d.php?t=571302

    42. BMW E46 Lower Lumbar Support DIY

    http://www.tmk.com/lumbar/

    43. E46 Engine Removal and Installation

    http://jbbeach.com/files/bmw323ci/11...llation_pp.pdf

    44. DSC / ASC E46 Information

    http://www.bmwtech.ru/pdf/e46/ST034/9%20Engines.pdf

    45. Are you installing a strut bar, that does not allow enough strut mount bolt to show (for fastening)?

    http://forum.e46fanatics.com/showthread.php?t=927849

    46. How to wet sand a panel on your E46

    http://www.zhpmafia.com/forums/showt...t=sanded+trunk

    47. E46 BMW Performance Strut Bar install Instructions~Attached

    48. ECSTuning Brake bleed procedure and information

    http://www.ecstuning.com/BMW-E46-330...1/Video247-SD/

    49. Replacing Broken Fog Light Lens


    -----------------------------
    Quote Originally Posted by terraphantm View Post
    Buy this cable: http://www.amazon.com/OBD2-Diagnosti...eywords=VW+409

    It won't have battery and ignition detect like a cable meant for BMWs, but that doesn't really matter. If that bugs you, look for a "D-CAN" cable.

    Then find DavidMc's 4shared folder (there's a link and password somewhere in the diagnostics section of bimmerforums) and download EDIABAS 6.4.3 and EasyDIS v44. There are guides on how to set all the software up.
    --------------------------------------------------

    Incase no one knows here's how to do it.
    Tests 1-2 are unlocked. Tests 1.2, 1.2 etc are known as sub-tests. Tests 3-21 are locked but Test 19 is the unlock function for accessing the displays.This should work with your vehicle.


    TEST 01. - Vehicle specific data including:
    SubTests:
    12345 1.0 = VIN
    7504 1.1 = Body number
    690151 6_1.2 = Part number of cluster
    039000 1.3 = Coding/Diagnosis/Bus Index
    1102 1.4 = Manufacturing date (calender week/year)
    06_110 1.5 = Hardware/software # of cluster (HW:06, SW:110)
    1E5_06 3_1.6 = injection status, number of cylinders, engine factor

    TEST 19. LOCK/UNLOCK
    Sub-Tests
    L-ON---
    L-OFF 19.0 =
    Displays changes from "L-ON" to "L-OFF" every second. To unlock test functions, press the cluster button immediately when it changes to "L-OFF". Tests are automatically locked when exiting test functions.

    TEST 02. - Cluster System Test - activates the gauge drivers, indicators and LEDs to confirm function.

    TEST 03. - SI Data
    Sub-Tests:
    1500 3.0 - Liters
    0 3.1 - Periodic inspection days (not applicable for US)

    TEST 04. - Momentary Consumption
    Sub-Tests:
    0267 4.0 = 26.7 liters/1000km
    0073 4.1 = 7.3 liters per hour

    TEST 05. - Distance Gone Consumptions
    Sub-Tests:
    0195 5.0 = 19.5 liters/100km
    226 5.1 = momentary distance to go (226km)

    TEST 06. - Fuel level sensor inputs in liters
    Sub-Tests:
    237415 6.0 = Fuel level aveg. *LH sensor input = 23.7 liters
    *RH sensor input = 41.5 liters
    0652 6.1 = Total tank level average = 65.2 liters
    0667 1_6.2 = indicated value and tank phase *1 = both sensors OK
    *2 = one sensor fault
    *3 = implausible input

    TEST 07. - Temp. and Speed
    Sub-Tests:
    032 7.0 = coolant temp. input 32C
    245 7.1 = outside temp. input 24.5C
    5283 7.2 = engine speed 5,283 RPM
    058 7.3 = vehicle speed 58km/H

    TEST 08. - Input values in HEX Form
    Sub-Tests:
    XXX 8.0-8.3 = Hex code, instrument cluster inputs

    TEST 09. - Battery Voltage
    Sub-Test:
    125 9.0 = 12.5v

    TEST 10. - Country Coding
    Sub-Test
    02 10.0 - US 02

    TEST 11. - Cluster Code
    Sub-Test
    000003 11.0 = Cluster Code

    TEST 12 - Not Used

    TEST 13 - GONG Test
    Sub-Test:
    Gong 13.0 = Activate gon by pressing buttong (gong response is delayed)

    TEST 14. - fault memory (NOT FOR DIAGNOSIS)

    TEST 15 to 18

    TEST 20. - Averg. fuel consumption - correction factor.
    The factor follows previous systems, with adjustment range of 750 - 1250. The adjustment method is new for the base cluster. If adjustment is necessary, enter into test 20 using the cluster button.

    The correction factor number is changed by using the sub-tests for the "ones, tens, and hundreds of the correction factor number. The digits will automatically scroll through 0-9 within each group (ones, tens, hundreds).

    Sub-Tests:
    XXX9 20.0 = Press the button when the correct "ones" position is attained.
    XX5X 20.1 = Press the button when the correct "tens" position is attained.
    12XX 20.2 = Press the button when the correct "hundreds" position is attained.

    TEST 21. - Software reset
    sub-test:
    reset 21.0 = Reset Software.


    OTHER USEFUL LINKS/PICS

    WINTER STORAGE OF YOUR BMW

    http://www.zhpmafia.com/forums/showt...Winter-Storage

    WHEEL RESTORATION ON YOUR BMW
    http://www.autopia-carcare.com/realwhda.html

    E46 FUSE DIAGRAM


    How does DSC work? Read below...

    http://www.bmwblog.com/2011/11/22/op...-lock-dsc-off/

    GOT TIRE CUPPAGE?

    http://www.bimmerfest.com/forums/sho...d.php?t=269181

    http://www.e46fanatics.com/forum/sho...php?p=11289924
    Attached Images
    Last edited by danewilson77; 05-08-2011 at 06:09 AM.
    "Flame suit NOT REQUIRED here on ZHPMafia.com"
    Call Me Dane l 2/2004 330i ZHP l 18x8 ET45 BBS CK's wrapped with Conti DWS's @ 245-40-18 l KW V1 Coilovers l BMW Performance Rotors l GruppeM3 Intake l UUC StrutBarbarian l Racing Dynamics Rear Strut Bar l Jim Conforti Shark Injector l Silver Cube Interior Trim l Bimmian Celly Mount l Weisslicht A/E's l M3 Trunk Mat l l e90 Performance E-Brake & Shift Knob l M3 Tri-Stitched Boots l AL Headlight Retrofit with ZKW Lenses l CobyWheel Wrap w/ M3 Stitching l LCM sw 4.5 triple blink and rear fogs l Maintenance B.U.O.S.S

    "We're here to commiserate, commune, and converse with one another on equal footing." ~Marcus Handy of Peerless Fine Art

  2. #2
    Great idea, DW. And as you guys do more of those DIYs, you can always change the link to somewhere at ZHPMafia.com.

  3. #3
    Join Date
    Dec 1969
    Location
    Lebanon, OH
    My Ride
    2/2004 330i
    Posts
    32,003
    Yeah...I was looking for what fit.....
    "Flame suit NOT REQUIRED here on ZHPMafia.com"
    Call Me Dane l 2/2004 330i ZHP l 18x8 ET45 BBS CK's wrapped with Conti DWS's @ 245-40-18 l KW V1 Coilovers l BMW Performance Rotors l GruppeM3 Intake l UUC StrutBarbarian l Racing Dynamics Rear Strut Bar l Jim Conforti Shark Injector l Silver Cube Interior Trim l Bimmian Celly Mount l Weisslicht A/E's l M3 Trunk Mat l l e90 Performance E-Brake & Shift Knob l M3 Tri-Stitched Boots l AL Headlight Retrofit with ZKW Lenses l CobyWheel Wrap w/ M3 Stitching l LCM sw 4.5 triple blink and rear fogs l Maintenance B.U.O.S.S

    "We're here to commiserate, commune, and converse with one another on equal footing." ~Marcus Handy of Peerless Fine Art

  4. #4
    Join Date
    Dec 1969
    Location
    Lebanon, OH
    My Ride
    2/2004 330i
    Posts
    32,003
    Updated with E46 fuse diagram....
    "Flame suit NOT REQUIRED here on ZHPMafia.com"
    Call Me Dane l 2/2004 330i ZHP l 18x8 ET45 BBS CK's wrapped with Conti DWS's @ 245-40-18 l KW V1 Coilovers l BMW Performance Rotors l GruppeM3 Intake l UUC StrutBarbarian l Racing Dynamics Rear Strut Bar l Jim Conforti Shark Injector l Silver Cube Interior Trim l Bimmian Celly Mount l Weisslicht A/E's l M3 Trunk Mat l l e90 Performance E-Brake & Shift Knob l M3 Tri-Stitched Boots l AL Headlight Retrofit with ZKW Lenses l CobyWheel Wrap w/ M3 Stitching l LCM sw 4.5 triple blink and rear fogs l Maintenance B.U.O.S.S

    "We're here to commiserate, commune, and converse with one another on equal footing." ~Marcus Handy of Peerless Fine Art

  5. #5
    Join Date
    Dec 2010
    Location
    Edmonton, AB
    My Ride
    2006 330CiC ZHP
    Posts
    108
    Wow! Thank you very much Dane for this thread, answered a few of my questions.

  6. #6
    Join Date
    Dec 1969
    Location
    Lebanon, OH
    My Ride
    2/2004 330i
    Posts
    32,003
    Sure thing pal....
    "Flame suit NOT REQUIRED here on ZHPMafia.com"
    Call Me Dane l 2/2004 330i ZHP l 18x8 ET45 BBS CK's wrapped with Conti DWS's @ 245-40-18 l KW V1 Coilovers l BMW Performance Rotors l GruppeM3 Intake l UUC StrutBarbarian l Racing Dynamics Rear Strut Bar l Jim Conforti Shark Injector l Silver Cube Interior Trim l Bimmian Celly Mount l Weisslicht A/E's l M3 Trunk Mat l l e90 Performance E-Brake & Shift Knob l M3 Tri-Stitched Boots l AL Headlight Retrofit with ZKW Lenses l CobyWheel Wrap w/ M3 Stitching l LCM sw 4.5 triple blink and rear fogs l Maintenance B.U.O.S.S

    "We're here to commiserate, commune, and converse with one another on equal footing." ~Marcus Handy of Peerless Fine Art

  7. #7
    Join Date
    Mar 2011
    Location
    Kittery, ME
    My Ride
    e46/e91
    BMWCCA Member #
    440234
    Posts
    373
    This is great.
    - Channing



    BMW Perf. Gloss Kidneys | UUC DSSR | B&M SSK | 35% tint | LED Plate Lights | Front Plate Delete | Aux Input.

  8. #8
    Join Date
    Apr 2011
    Location
    San Jose, CA
    My Ride
    04 zhp
    Posts
    47
    This is amazing..

  9. #9
    Join Date
    Jan 2011
    Location
    San Ramon, CA
    My Ride
    Imola Red ZHP.
    BMWCCA Member #
    334619
    Posts
    273
    Very nice! Nice touch with the videos for DIY's!
    2004 Imola Red over Black Leather. 6-MT, Navigation, Cold Weather Pkg (the wife loves them seat warmers!), 3.46 Diff, UUC Short-Shift Kit, Tranny Mounts, CDV Delete and iPod mount.

  10. #10
    Join Date
    Apr 2011
    Location
    Baltimore, MD
    My Ride
    05 330i ZHP
    Posts
    50
    This is fantastic. Thanks for your efforts.
    Jet Black. Still Stock ...with tint.

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