zak's 04 330ci ZHP fix it project.

[zak]

Well where to start,... I hit a deer with my car and the insurance totaled it and I have retrieved it and stating the fix it back up the segment of my limited ownership of my brother's car. My intro thread in New Members (http://www.zhpmafia.com/forums/showthread.php?20876-Wisdom-of-the-forum-needed) thread has the details.

I have the car home now and starting to hunt for some parts to get it back together.

I am looking at this M3 that is close to me... Differences on the M3 to my 04 330ci ZHP? Question, will it work? Do i need to buy the hood both fenders and the front too get everything to line up?... https://minneapolis.craigslist.org/ank/pts/d/e46-m3-part-out/6452568799.html

The damage..
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The haul home 40mph winds on the way down to Newcastle WY, but a nice evening.
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As it sits now.
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[bandwagn]

The M3 didnt get any of the LCI updates, so is a bit different to begin with - that said, not sure if it would just bolt right up or not.

[SaltyNC]

Check this out, Zak, and sorry about your car, man.

http://forum.e46fanatics.com/showthread.php?t=507208

Salty

[SaltyNC]

This might help, also:
http://forum.e46fanatics.com/showthread.php?t=426625

Salty

[zak]

SaltyNC
Thanks for the links, heading there now...

[zak]

The parts that I am looking at from the M are... Let me know if I am missing anything to make this work.

Hood with hinges
Both fenders and liners
Front bumper with driving lights
Headlights
Sidelights
Radiator support with front cowling
Lower wheel splash with brake vents.

[ELCID86]

Sorry that happened. Glad it wasn’t worse and you felt it back. Looks like the middle of nowhere!

[zak]

Thanks, yup middle of nowhere it is.

[cakM3]

Zak, I’m glad to see you’re fixing her up (saving her) instead of allowing her to go to the wrecking yard. [emoji1419]

When you replace your front radiator support get the one for verts. They are reinforced and are a stronger part compared to the coup part. [emoji1417]

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[johnrando]

Good to know it will be back.

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[zak]

Thanks all...
Did a little test fit with my new parts the other day...
Looks like the M3 parts may fit.
I see the washer bottle is behind the bumper.... what do you guys think, use it or not.

Also any sponsor vendors I should look at for the cooling system refresh.

Giving taptalk a try, not crazy about it, any other apps for this site?https://uploads.tapatalk-cdn.com/20180201/f6718e0258ef5c6882e4daadeebeb02f.jpg

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[nextelbuddy]

are you using the kevlar bumper support for your M3 front end or do you have the aluminum bumper support? each one has a different washer tank. did yours come with the proper tank?

[SaltyNC]

Zak, I don't know if they are a sponsor, but FCPEuro has the BMW OE expansion tank. It's a Modine unit. When it arrived the front had a sticky spot, and it is literally where they removed the BMW part number label, and they Dremel off the BMW logo imprinted on the tank. I had bought a Behr-Hella unit, but I asked several people that had installed it (including 50sKid that has the E46 YouTube channel), and they had leaked, so I sent it back. Comparing the two, the Modine unit looks superior.They also sell the Saleri OE water pump, and all other components you would need. I ordered most cooling components that are OE, just not stamped with BMW. I did go with the aluminum water pump pulley instead of OE plastic.

You got the M3 pieces fast. Looking good.

Salty

[zak]

Salty, yep i got the washer bottle with the front parts, it has the carbon support with the washer bottle that mounts behind the bumper and just the filler neck sticks up into the engine bay.... sure would open up some space.

I know my other brother and Barry put on some new pulleys before Barry got to sick.
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[cakM3]

If you’re going to use the M3 front fenders then you better do the rear quarters and OEM M3 Rear bumper or the car won’t look right.


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[zak]

If you’re going to use the M3 front fenders then you better do the rear quarters and OEM M3 Rear bumper or the car won’t look right.


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I hear ya, it will be a bit of a bastard for now. The pic sure exaggerates the flare from that angle.
I have been on the hunt for some m3 rear Parts, and an S54.

[zak]

are you using the kevlar bumper support for your M3 front end or do you have the aluminum bumper support? each one has a different washer tank. did yours come with the proper tank?

Yes, and the aluminum hood with hinges. I went thru your thread to find the engine swap, I am hoping I can pull it off in my garage.
1st I to need swap the engine in my KTM adventure for a little more snoot.

[zak]

Well, I finally got time to get back on this project! It was a long hard summer of getting my family home of 55 years ready for the market, moving and getting moved in to the new place set up a new speed shop (garage) and new home.

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sand wipe sand wipe repeat.
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got the inner fenderwell pounded out and pulled up to get the front cover and fender to line up.
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thats how the other passenge side gaps.
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[zak]

prep... primer..sand.. wipe.. repeat..... 2 coats of primer wet sanded out.

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New urethane primer, 1-hour pot life... guess its been a while since I sprayed any auto paint.
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[zak]

I put the old radiator in to see if this was going to work with the rest of the m3 radiator support, tested the fan motor and the headlights. Got a refresh on how this jigsaw puzzle goes back together.

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It actually bolted back together. This might work..:dunno
So I ordered up the parts needed to get it running.... you know radiators expansion tank water pump hoses..... blah blah

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[RUS_ZHP]

That's a very impressive paint prep work my friend! Great job!


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[johnrando]

+1, great werk!

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[zak]

Thanks...

Hey guys i am going to do the oil filter housing gasket while everything is still opened up.
Anybody have any wisdom for me or a thread that may detail it.

? pull the filter suck out the oil remove and replace ?

I thought my brother had a repair manual for this car but cant find it... do i need to have torque specs for water pump and pulleys? any online source for these and others?

[pedro2u]

50sKid did a video:

https://www.youtube.com/watch?v=zC_cmsX68Ok

[zak]

Nice, thanks...^^

[cakM3]

Regarding the front radiator support, I would suggest using one from a vert. The vert front radiator support is much stronger and is reinforced.

I replaced my M3’s front radiator support for the vert part and could not believe just how much more firm my chassis is with the vert part installed.


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[zak]

I think that's the second time you told me that, thanks. Yep, this one sure is flimsy-flexy.

[pedro2u]

most of the specs here:

https://forum.e46fanatics.com/showthread.php?t=1065428

and for your reading pleasure: the PDF of the Bentley bible - 1258 pages of light reading!

http://bmw.n84.eu/e46/E46_Bentley_Service_Manual.pdf

[zak]

Thought I should do something about the crumbling wire protection, it's only the wires that go to the cam timing sensor and more... Dropped a piece in the same size then wrapped it with another.

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[zak]

Thanks again, Mr3000. You're saving me a bunch of time from navigating thru the forums.

Editing my posts is sort of kicking my azz on this site.

[zak]

Looks like 10mn for this size bolts and nuts... same as on my bike, good to know. 1/4 inch ratchet choked up on it is my 10mn. I will check them with a torque wrench.
Posting these for my quick reference.

Thermostat
1 of 3 Identical Bolts (Part Number 11531740317)
7.3 Ft Pounds
9.9 NM

1 of 1 Bolts (Part Number 11531740316)
17.7 Ft Pounds
24 NM

Coolant Pump
Pump
7.4 Ft Pounds
10 NM

Pully (4x 07119904524)
7.4 Ft Pounds
10 NM

Belt Tensioners & Pully (Both Mechanical & Hydraulic)

Main Belt
17.7 Ft Pounds
24 NM

A/C Belt
34.7 Ft Pounds
47 NM

Drive Line Belt Pully
34.7 Ft Pounds
47 NM


Alternator
Short of the Two (125 MM)
47 Ft Pounds
63.75 NM

Longer of the Two (150 mm)
47 Ft Pounds
63.75 NM

Oil Filter Housing Bolts (For Accessing Oil Filter Housing Gasket)
15 Ft. Pounds
22 NM

Vanos Oil Hose from Oil Filter Housing (Hose with Hollow Bolt)
23.5 Ft. Pounds
32 NM

[zak]

Looks like the pulley tensioner was weeping and the oil filter housing gasket was still doing its job, the new one goes in tomorrow.

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What's up with the waves in the oil filter? Normal or not.

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[zak]

So I watched the kids video and he had the torque for the alternator of 17 fps and the bolt mega thread (https://forum.e46fanatics.com/showthread.php?t=1065428)has 47 fps... 47 wow... Sure seems like a lot.

I found quite a few threads on the subject... Anyone want to chime in.

There are 2 bolts that hold it onto the mounts upper with a pully and lower, can't imagine putting that much on the lower.

[Sockethead]

47 lbs seems pretty high... I've found that most of BMW torque values to be lower than what I would expect. I have a Bentley at home. If no one posts by then I'll see what it says.

[DeathTrap]

Oil filter is normal. It's what happens under pressure I'm guessing. Both of my BMWs do this.

[zak]

Oil filter is normal. It's what happens under pressure I'm guessing. Both of my BMWs do this.

Thanks.

A wavy oil filter on my motorcycle is the first signs of water pump failure...coolant in your oil.

[zak]

These are the 2 alternator bolts i have questions about torque. Top one has the pulley and bottom is just a bolt.

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[Sockethead]

I looked in the Bentley manual. There is no torque values listed for the alternator bolts... Very strange.

[BMWCurves]

I looked in the Bentley manual. There is no torque values listed for the alternator bolts... Very strange.

I'd just go with "won't fall off" ft-lbs of torque.

[zak]

Haha... me too, I spent some time last night till I couldn't see straight looking thru the PDF that mr3000 linked and could not find anything for this also... I copied every torque spec to a word doc filled about 6 pages.

Thanks for the effort.

I think 24 nm or 17 ftp is what I am going with.

[zak]

I'd just go with "won't fall off" ft-lbs of torque.

Right on...:thumbsup

[zak]

Score... had to do some digging, moving sucks.

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So they say pulley to alt (M16 nut)...70 nm 44 ft-lb...... That is the nut for the pulley on the front of the alternator.

And they give the B+ wire to alt.... (M8 nut)...13nm 10 ft-lb.... The cable to the battery
No mention of the mounting bolts... I am sticking with 24 nm

[zak]

Hey got a question about the headight washers... never used them before, how do they activate?
Headlights in side markers in driving lights in windshield washers all pluged in... all still hanging loose to test the new washer plungers and new nozzles.

Any insight is appreciated. The owners manual says pull back on washer lever... Got no love.

Windsheild washer works.

[az3579]

Hey got a question about the headight washers... never used them before, how do they activate?
Headlights in side markers in driving lights in windshield washers all pluged in... all still hanging loose to test the new washer plungers and new nozzles.

Any insight is appreciated. The owners manual says pull back on washer lever... Got no love.


The headlight washers only activate every 5th windshield wash.

[zak]

Thanks, just went thru the Bentley and saw that... still a no go.

The fluid will run out of the plungers with the nozzles removed..

[johnrando]

Lights on, every 5th one.

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[zak]

]Thanks, yep lights on even tried with driving lights on. No joy...

New plungers and nozzles.

I took one of the nozzles apart to see how the back flow blow off valve works, and tried lubing the rubber plunger inside the nozzle to get it moving smooth. I even got out my old bicycle tire pump to see if i could get air to move thru.. it takes a fair amount of pressure to open the the valve to release and let air pass.

In my box of parts i found another washer pump that i dont remember where it came from.... been over a 18 months ago when i took my busted up front end off.

So dose the pump on the washer fluid tank run both windshield and headlight washers?

I am going to try some more tomorrow and I'm not going to spend the whole day on it like today, if i have no luck its delete time.

My body parts go in on Monday for paint, its getting close and I am ready to have it back together....

I started it a couple months ago, so it still runs... with the old gas, that was a relief.

[zak]

Did an oil report when i changed it, passed.

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[zak]

Can the Headlight washers be coded out?
I know Barry did some tweaks to the code for something.

[ELCID86]

Can the Headlight washers be coded out?
I know Barry did some tweaks to the code for something.

Yes they can be.

[az3579]

]
So dose the pump on the washer fluid tank run both windshield and headlight washers?


There is a separate pump on the washer reservoir for the headlight washers. There's one closer to the headlight and one that's further back. The one that's closest runs the headlight washers.


Can the Headlight washers be coded out?
I know Barry did some tweaks to the code for something.

Yes they can be coded out.

[zak]

Thanks, going to leave them hooked up and check into that. My brother was very picky and i don't think he would like the washer fluid running up the hood, feels to me like it would be something he would do. I still have his laptop that has the software on it.

[zak]

There is a separate pump on the washer reservoir for the headlight washers. There's one closer to the headlight and one that's further back. The one that's closest runs the headlight washers.



Yes they can be coded out.

Thanks you guys are big help.

Pic of the front pump for the headlight washers. Going to have to get a hand to check if that pump is pumping.
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[zak]

Success!
Put in the spare pump that I couldn't remember where it came from and its squirts like nuts now, the old one made noise but no pressure.. And... wait for it.
.
.
.
its got a dripper from somewhere, will look into that... haha
.
.
No more leaks, mucked up an o ring.

[johnrando]

So fixed? If so, good stuff. Or do u still need to do the o-ring?

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[zak]

Yup, fixed with a new o ring, mucked it up pulling it apart so many times... And no leaks over a couple days.
Looks like the spare pump came from the M3 washer fluid tank i got with the parts i bought.

[zak]

Well its a car again...
Had a bad projector bulb that i could not get out with the headlight in, the bulb was jacked up in the socket not allowing me to get it out.
I had forgot how fun this car is... almost looped it out in second going around a left jog in the road. I guess 5 grand full pedal and a bit of sand don't mix...

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[Will]

Wow, nice work!!! Paint work looks awesome, and well done with the "jig-saw puzzle" of piecing the front end back together. Great job saving a nice car!

Did you spray that in your garage? You might have to put together a DIY thread on it. haha.