9 years later I've joined the ZHP gang

[MINIz guy]

I created this account back on April 9, 2012. I was in high school back then. Now, nearly 9 years later, I've picked up my first E46 and it happens to be a ZHP. It's nothing special, extremely ugly and needs lots of maintenance. Key things to note are 223k miles and a $2k purchase price.

I'll post more tomorrow after I inventory everything wrong with it. It's been a long day of trailering.

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[fredo]

Welcome, sir. Congrats on your ZHP. Please post more details when you have them.

[cakM3]

Congrats on the pickup.... now let the fun begin :thumbsup

[joeybananaz18]

im gonna go out on a limb and say thats the best 2k you'll ever spend- that M54 is just broken in. congrats and welcome!

[Oli77]

Gorgeous silbergraw!

[MINIz guy]

Tore apart the front end and removed all under trays and fender liners. Surprisingly no rust in the fender wells! I think the OFHG is leaking, and possibly the pan. The steering is very loose, feels like inner tie rods. Water pump looks original too. The list keeps growing....

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[t.er]

Welcome! I was always into Japanese cars when I was a kid, and found my love for older BMWs when I worked on a couple E36s in high school - I was actually looking for a clean E36, but my ZHP popped up for sale when I was in 1st year uni and the rest, as they say... is history.

If that ZHP runs decently for $2k that's already a steal! Looking forward to following along your restoration.

[BMWCurves]

Welcome!

[johnrando]

Welcome back! Congrats on finding one.

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[BADCLOWN]

congrats on the purchase, my first ZHP was the same color. the rehab project should be fun

[pedro2u]

Welcome and congrats. Check those front control arm bushings - they could be shot! Easy quick fix for that at least

[MINIz guy]

Finally checking out the pictures on a computer and Tapatalk really butchered the quality.

Had a chance to look underneath the entire car yesterday and it has really good bones considering how the exterior looks. It reminds me of how I picked up my E36. I don't even need to address the jacking points anytime soon as they are in good condition, and all 4 pads are present. I pulled the seats out to clean the interior and try and revive the seat foam. The alcantara needs some help too.

The bad part is that it needs a rack rebuild, probably the biggest part expense. I pulled a boot and a few ounces of ATF dripped out. I also felt all the ball joints while my dad shimmied the wheel; there was slop everywhere and I think I'll need to redo it all. Now the scope creep sets in as its not hard to weld in the front subframe reinforcements and secure the OPN when the control arms and steering rack are out of the way. Same goes for the back since the diff bushings are shot and I'll be doing the RTABs; the only thing stopping me from dropping the entire rear end for RTAB pocket reinforcements and subframe reinforcements is time.

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[BADCLOWN]

someone is selling a ZHP rack in the classifieds right now I believe

[MINIz guy]

I saw that and considered it! Got lucky and found a local junkyard with a 138k mi ZHP and a steering rack still intact. We'll see if that one is leaking/still the original 712 rack when I go pick it up.

[BADCLOWN]

Nice pick up, cant imagine finding a ZHP in a junkyard is very common

[MINIz guy]

Yellow tag rack out of a 138k mi ZHP! Hopefully I get some life out of the tie rod assemblies to keep the budget down.
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[MINIz guy]

Anybody notice the issue?

https://uploads.tapatalk-cdn.com/20210412/4a062e4bbcd68671235f33212c62dba9.jpg

Yes, the PO had good intentions while replacing the steering coupler with an OE BMW one. However, he put the bolts in backwards and stripped everything out.

The junkyard rack is in, along with the old coupler and tie rods that came with it. Steering feels normal again!

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[MINIz guy]

Took apart the passenger door to get to the regulator. Unfortunately it's too far gone to do the zip tie fix. The good thing is that the PO did install the full Bavsound kit and added extra sound deadening!

https://uploads.tapatalk-cdn.com/20210424/da2377a5ee082b268967660806391250.jpg

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[johnrando]

Nice!

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[MINIz guy]

How many years of forgotten brake fluid changes causes this? Another small maintenance item knocked off the list. And to why progress is slow, well I'm budgeting $100/mo and that doesn't many car parts. I have a few parts left to install, but only after I get my E36 running again.

https://uploads.tapatalk-cdn.com/20210430/2dab7435d2dbb65c31f0b135247fc35f.jpg

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[cakM3]

How many years of forgotten brake fluid changes causes this? Another small maintenance item knocked off the list. And to why progress is slow, well I'm budgeting $100/mo and that doesn't many car parts. I have a few parts left to install, but only after I get my E36 running again.

https://uploads.tapatalk-cdn.com/20210430/2dab7435d2dbb65c31f0b135247fc35f.jpg


I had a similar experience when changing out brake fluid on my ZHP. This is something that should be changed out every two years but it seems people overlook this essential maintenance.

This is how my brake fluid looked when Botond helped me flush out the brake system on my ZHP…
https://uploads.tapatalk-cdn.com/20210430/3ac17d152c09be9e79bc5c567d3dfe1f.jpg

Until then, I have never seen brake fluid so dirty[emoji15]


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[MINIz guy]

Yup I should bleed the slave too, as that fluid has to be nasty as well!

Another day waiting for a window regulator and nada... At this point I could have dropped the diff and done the bushings while waiting, but hindsight is always 20/20. Need to put some mileage on it to diagnose a sporadic misfire on one cylinder, which I think is due to a coil.

[cakM3]

Need to put some mileage on it to diagnose a sporadic misfire on one cylinder, which I think is due to a coil.

What I did on my first ZHP when it had a bad coil pack was to change all of them out. Not that I had to but I am in the mindset that once a coil pack starts to go it’s only a matter of time the others will start going bad as well so that’s why I will just swap all of them out when swapping out coil packs.


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[MINIz guy]

Yep, I'm sure the coils are tired. It has a new coil and 5 original ones already. INPA said the car had a cyl 6 misfire but no CEL on. I swapped that coil to cyl 3 and then INPA recorded a higher positive value on the "rough running" monitoring page. Still, everything in the green so it isn't running that terribly.

I took this photo after the window regulator went in. Paint doesn't look too bad here!
https://uploads.tapatalk-cdn.com/20210503/6f5fd359e2dd83944b0b2e47b82f4fde.jpg


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[MINIz guy]

Finally the diff bushings are in and the car doesn't clunk as if the subframe is falling off. I had to lower the subframe a little to get my press tool in there and got a good look at the front mounting points. There are no visible cracks on the subframe floor, but I'll have to reevaluate when I prep the area for reinforcement plates.

https://uploads.tapatalk-cdn.com/20210510/383f00341dc50dbccb1004dc14795a26.jpg

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[MINIz guy]

VCG and OFHG completed today. Looks clean for 223k miles! Still working on the water pump since it's accessible after the OFHG.

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[MINIz guy]

Water pump job was cake. It still had the original pump from '04 in it and it was quiet and showed no play at 223k miles. I kept it as a spare for emergencies.

The RTABs were next and those too were stamped '04! No wonder why the rear end felt like jello. They were rusted in there pretty good too as the sleeve fell apart when being pressed out.

https://uploads.tapatalk-cdn.com/20210523/d3879382c8cd0361ac26f02e09a469fa.jpg

I still have an oil pan gasket to do, but my engine support bar is backordered. Oh well, my parents X6 broke a belt tensioner today so that'll keep me busy tomorrow.

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[MINIz guy]

https://live.staticflickr.com/65535/51199052048_0955e57789_b.jpg

Finally a non-compressed Tapatalk picture thanks to Flickr! Can't see the fading paint from this angle :rofl

[johnrando]

Nice werk.

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[MINIz guy]

No big updates, just enjoying the summer in the city and track time in my E36. Uncovered the ZHP and took it for a drive, and amazingly the airbag light went out. I'll take it!

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[MINIz guy]

Alright oil pan gasket time! Currently mid-job. Had to tackle a strong fuel smell coming from the fuel filter area beforehand. The hose there was cracking and letting vapor out; it was very close to leaking!

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[cakM3]

Love seeing good progress being made to restore this car... AWESOME WORK! :thumbsup

at least you didn't have some dumbass glue your hood insulation to your hood like the previous owner did to mine...SMFH...

[MINIz guy]

[emoji23] no hack job things on mine so far, just lots of neglect.

The oil pan is back on for the night. Turns out somebody had been in there before as I found remnants of red RTV there. I also think there was Loctite (blue) on the oil pump nut as there was something on the threads. I threw on red Loctite and safety wired the nut for piece of mind. I thought about adding a baffle, but since I plan for SE46, the motor has to come out anyway and I'll baffle the new motor then. This car will sit around a lot as I go to grad school for the next 2 years.

Tomorrow I weld on the front subframe reinforcements and finish up reassembly.

https://uploads.tapatalk-cdn.com/20210722/6ab4712448f2fbc4d974223fbcd181aa.jpg

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[MINIz guy]

I hate welding in the subframe pocket. Couldn't get it clean enough and the welds were super dirty; I created lots of splatter. Oh well, the outside welds look good!

https://uploads.tapatalk-cdn.com/20210722/6ad27a4b2c5897538ac707296805f409.jpg

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[MINIz guy]

Don't forget to plug weld the other side to reinforce the subframe fully. All painted and waiting to dry.
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[cakM3]

Impressed!!! :thumbsup

Glad you're able to do the welds like that... I'll just pay someone to get mine done if I did this....I make up for it with my detailing skills...

[johnrando]

Nice werk! [emoji1360]

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[MINIz guy]

Finished up and went for a drive to crest 223k! Waiting for paint to dry took the longest today, welding prep took the second longest.
https://uploads.tapatalk-cdn.com/20210723/1a4e217d7a2f7c543104821adbe87005.jpg

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[MINIz guy]

https://youtu.be/gsJIQx2NWNs


https://youtu.be/gsJIQx2NWNs


Back working on my ZHP again. Decided to film the work for my YT channel instead of grabbing a million pictures. It got a new radiator, FCABs, tie rod assemblies, rear ball joints, RTAB limiters and hood pins. Give it a view if you have time!

[MINIz guy]

39815

Wow, an update! You already know what’s happening. Subframe and RTA pocket reinforcement time.

[Oli77]

Holly Molly!

[RUS_ZHP]

39815

Wow, an update! You already know what’s happening. Subframe and RTA pocket reinforcement time.That is a tough task to do in the jack stands. I did it once and it was PITA.
Good luck! This is a definitely great thing to do on our aging cars. I replaced everything single bushing, when I did my reinforcement.

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[MINIz guy]

That is a tough task to do in the jack stands. I did it once and it was PITA.
Good luck! This is a definitely great thing to do on our aging cars. I replaced everything single bushing, when I did my reinforcement.

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It's a job I'm all too familiar with. I did everything on my E36 a few years ago. Taught myself how to weld on my back with that car.

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All the rear bushings/bearings are new besides the subframe ones. I have Revshift ones going in with this job. I'll also be throwing on M52/S52 headers and the BW SE46 exhaust. I'm also contemplating a shifter rebuild and a clutch since everything is apart, but we'll see how motivated I am in this TX heat!

[RUS_ZHP]

It's a job I'm all too familiar with. I did everything on my E36 a few years ago. Taught myself how to weld on my back with that car.

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All the rear bushings/bearings are new besides the subframe ones. I have Revshift ones going in with this job. I'll also be throwing on M52/S52 headers and the BW SE46 exhaust. I'm also contemplating a shifter rebuild and a clutch since everything is apart, but we'll see how motivated I am in this TX heat!Welds looks great. I hired my friend to do it since I am skilled.
I've heard a lot of good things about S52 headers from my friends, who track their cars. They love them.

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[MINIz guy]

Never buy an E46… found cracks on the drivers rear which was typical. I also found a crack on each side of the RCAP where it mates to the wheel well. The longest was on the passenger side. Good thing Redish has so many videos in this I know exactly how to tackle it. I think I see the light at the end of the tunnel!

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[MINIz guy]

This was way tougher than my E36. The plates went on fine. The wheel arch and spot welds I had to repair gave me so much trouble since I couldn’t clean the area out enough. Got a few new tools out of the job such as carbide bits and a spot weld cutter.

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[MINIz guy]

And a few seam sealer and painted shots. Need to weld the bracket for the e-brake cables and subframe bracket back on for the body work to be complete. I still need to paint the subframe… boy am I sick of paint prep.

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[MINIz guy]

Rear sway bar reinforcements and finally engine work. The coolant pipes look original indicated by the blue zip ties. Going to be deleting the SAP, purge valve and heater hoses now. Finally getting towards track car status…

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[MINIz guy]

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Man no love for the Stimmy package car… finished up the coolant pipe. Removed the heater core hoses and blocked the pipe off at the head using the BW kit. Also installed the SE46 exhaust and sent it out for an autocross.

Weak points are the lack of an LSD and a clutch that started slipping on the way home. I did pick up a GC kit just for the camber plates as the car is plenty capable and fun on stock suspension. Any clutch and flywheel recommendations?

[johnrando]

I always heard OEM clutch is fine but I'm no expert.

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[MINIz guy]

I'm a glutton for punishment so I went with an eBay Clutchmax kit. We'll see how this goes!

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[cakM3]

I'm a glutton for punishment so I went with an eBay Clutchmax kit. We'll see how this goes!

Interested in seeing how this goes! Good luck :thumbsup

[MINIz guy]

Interested in seeing how this goes! Good luck :thumbsup

Thanks! I'll definitely take some photos and video the process. In the meantime, I finally edited and narrated my subframe job.


https://youtu.be/6JkI-nNIJcQ

[t.er]

Seeing all that work... I'm so glad to have been there and done that. If something were to happen to my car, I'm unsure if I'd pick up another E46 just because I'd have to do all that over again

[MINIz guy]

Seeing all that work... I'm so glad to have been there and done that. If something were to happen to my car, I'm unsure if I'd pick up another E46 just because I'd have to do all that over again

Since the E36 is so similar, this is technically my second time doing this. Like I said, glutton for punishment :biggrin I edited the intake manifold and exhaust portion of the work now, so this brings the videos up to speed. I'm currently working on dropping the transmission and hope that finishes up the drivability aspect of this car. Then I can focus on getting the GC coils and the Jim Blanton diff installed.


https://youtu.be/fjw-KCmQwSg

[MINIz guy]

39915

Yep, that's pretty worn.

[MINIz guy]

https://youtu.be/f8-9svwF60g

This is one of the longest videos I've edited, and it takes you up to everything before the transmission goes back in. I'm now on day 7 of waiting for my FCP parts to arrive. Transmission seals, pivot fork, guide tube and shift carrier parts are preventing me from buttoning it up this job!

[MINIz guy]

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Been driving around the past few days with the ClutchMax stage 2 kit. I used an INA pilot and throw out bearing. The clutch pedal is more effort than OEM as expected, but certainly fine for daily driving. I also replaced some alarmingly cracked front brake hoses with some new rubber ones (why buy SS when they are reinforced internally?)

Video to come soon

[av8drvr]

Curious to hear how transmission re-install went. I managed to get mine dropped yesterday, and boy was that not a fun experience. I honestly can not think how I am going to get the top 3 bolts in. I have some scope creep as my CSB was toast so waiting on a few more parts from FCP before I can put back together. I am following your YouTube, keep it up!

[MINIz guy]

Curious to hear how transmission re-install went. I managed to get mine dropped yesterday, and boy was that not a fun experience. I honestly can not think how I am going to get the top 3 bolts in. I have some scope creep as my CSB was toast so waiting on a few more parts from FCP before I can put back together. I am following your YouTube, keep it up!

Took me an hour to align and re-torque all the bolts. Use the jack to your advantage and tilt the base to get the input shaft to line up. Keep the transmission in gear so you can spin the output shaft, and it'll slip right in when the input shafts aligns with the clutch disc. Grease the dowel pin for the starter and it will go in easier, but I still used the starter bolts to pull it in all the way.

To get to the top 3 bolts, I had to lower the front subframe by 3/4" anyways. So on reinstallation, the extra clearance gave me ample room to fish my extensions and bolts into their holes.

[MINIz guy]

https://youtu.be/n3vBSjWWipo

And the clutch video is up!

Next up, Ground Control coilovers. I'll probably be cutting the strut towers to get the camber plates to fit :devilish

[MINIz guy]

Cut the strut towers to allow for maximum camber
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This is static camber up in the air. It’s close to 5 degrees!
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However when down on the ground, the coil overs are slammed. It’s on 6” 500lb Eibach springs and GC Race plates. Struts came off an M3 with Koni inserts. I hate piecing together suspension, but it looks like I’m going to need a 1” spacer to get the ride height I want. The rear is still on stock springs. The Koni oval track rear shocks are longer than the original shocks, so I’m going to need helpers to keep those springs seated when I’m jack the car up. It also means the rear can’t be slammed to match the front. Way more work than I expected for a set of $500 coils.
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[MINIz guy]

Did you buy the right car if you don't look back at it when walking away? I'm pretty happy with the progress of this car so far. Coilovers figured out and brakes installed for my track day on 9/9

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https://youtu.be/JP5PVnIc-BM

[MINIz guy]

Took the ZHP to two track days and experienced why you don't buy used dampers. I shook it down at MSR Cresson and found out quickly the rear Konis were blown and I was hitting coil bind. Fixed that by installing the stock Sachs shocks back on and went to ECR. I'm still battling front droop issues as I've never had so much trouble trail braking. Luckily, no damage to the car or myself after these two days.


https://youtu.be/l0e_DkOtSpM


https://youtu.be/aIP7CgcHFf0

[MINIz guy]

Next step in ruining the ZHP, sunroof delete! I can’t wait to tear apart the rest of the interior after my next 2 track days.

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[MINIz guy]

Welp this is the car now. I did a few tracks since the last update, then tore it apart. It’s reassembled now and ready for Willow Springs this week!

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