Z3 M Coupé Resto and Engine Rebuild !

[Clubber]

Engine coming along nicely. Cams and flywheel have been installed today and as always lots of more cleaning done.







Alternator serviced and cleaned,



Starter motor cleaned,

Before,





After,





and finally, new BBS center caps have arrived. Current ones are very worn and scratched.




Thermostat housing cleaned,

Before :



After :



Fuel rail cleaned and painted matt black for OEM look,



Housing installed and pulleys painted ;



Injection Tube Connecting Pipes cleaned (It's the little things

Before and after,



Throttle bodies installed,



And I bought an used headers which didn't have any cracks or welds and all it needed was some love,

Before,



Obviously this rusty junk can't go in to my fresh engine like that so, I sent it to my polish guy. He rested the headers in rust remower chemical for a day and the next day, he polished the metal using three different polish pads from hard to soft. The result,



That's it for now, more to come...

[Clubber]

We closed up the engine, engine cover repainted in OEM matt black. Needs a little cleaning but a whole lot better than the ricer grey paint before,







Then I saw the transmission laying on the side of the shop and decided to give it a good cleaning. I forgot to take a before shot but I can tell you it was almost completely black from dirt and oil.

found this pic online, not mine but mine was even dirtier,



And after a lot of pressurised water and other stuff,



My mechanic told me, in a few days, he would put the engine in so today, I cleaned up the engine bay as much as I can and man did it loose some dirt. It is really hard to capture the clean look on camera but you guys will get the picture I guess.

Before main look,









After, general look,



Steering rack before,



After,



Before,



After,





more to come...

[Clubber]

We received a bunch of small stuff including a lot of clamps, bolts and cosmetic stuff like covers and bins etc.

New cylinder head side cover,



new washer fluid reservoir,



and tested a heat shield cleaning on the undercarriage, turned out pretty good,

before,



after,



Just when we were having fun with cleaning, I got a call from post office and this arrived. Wanna guess whats in ?



No, it's not a home theater system



Finally my CF airbox has arrived and since the engine was in display only mode, we tried it on for wannabe race engine look









It looks all business, best money spent on the engine IMO. That ghetto sticker will come off, don't worry. It will be replaced with a " BMW M Power " sticker. next, the engine goes back in

[Clubber]

The engine went in, most of the cabling are done, wheels and calipers are restored.

First, we took of all four wheels cuz the lips on the BBS rims had slight clearcoat peeling and scratch marks on the edges. I took them to my wheel guy to have them dismantled and cleaned. He took them apart and cleaned each lip,







Inside the rims were filthy,



Since the wheels were apart, I decided to polish the lips for a change since my polish guy is awesome, I thought they might look good.

Before they came back from the polisher, I found the opportunity of having the calipers and wheel wells out in the open, so I decided a through clean of the area,

Front Stoptech BBK Calipers before,







They needed major cleaning and some touch up. I emailed Stoptech to ask for their red color code but they said they don't have one and the closer code to their paint was Dodge Viper Red. I found the paint code online and went a paint shop to produce a small amount for touch up.

Viper Red,



The color seemed too bright for my calipers untill I found out have much filth and dirt was covering the real color of the calipers, so we gave them a nice clean and scrubbing.





And after a lot of touch up, here's how they looked,

[0-60Motorsports]

This was an awesome build. Beautiful car.

[Clubber]

Originally Posted by 0-60Motorsports

This was an awesome build. Beautiful car.

Thanks my friend.

[Clubber]

Then we moved on to the rears, OEM calipers looked worn and the disc base was all rusty, We gave spray black to the calipers and spray silver to disc bases for OEM look,

Here they are before,



After cleanup and paint, much better,





and the next day, my wheel guy called me to check the wheels polished before he mounted the tyres, they looked great







After my approval of the splendid work, they went on the car,









and finally mu lonw awaited injectors arrived as they were the last missing parts for engine start up,



All lined up and installed,





Later on, the transmission will go in and mated to the engine. Then there will be some welding on the exhaust as there is a slight line up problem. Later in the week, we plan to start up the engine with CF airbox and continue with ecu mapping for it. Keep watching !

[alexk]

Make sure you remove the paint from the hub of the brake discs (that the wheel attaches too).
You might have issues with bolts getting unbolted.

[CraigMillwardCroft]

Nice rims

[Clubber]

I just realized I didn't finish up this thread.. Let me continue ;
Cleaned up some of the heat shields under the trans,



Missing additional fan came and installed,



Wheel bolts looked worn and rusty, so a fresh coat of paint helped,



and finally the radiator was cleaned, you wouldn't believe the amount of dirt came out of that thing. Just take a look to see the difference,



Later on, CF airbox is mounted,



Here is a short video of the first start -up,

S50 rebuild start-up - YouTube

Then we started reassembling some of the new parts like water bottle, radiator heat shields, o2 sensors, additional fan, bits of interior (center console etc.)









airbox in all its glory



Later on, we moved on to closing of the disastrous holes of the hood pins. The holes are filled before paint.
,

With these works, we arrived at the final stage which will include ; adding a cat for comfort ( way too loud now that the turbo is off )
Fine tuning the Alpha N Tuning on the ECU
Painting the hood and bumpers ( due to stone chips and aero stuff mount holes )
Reconditoning the interior and adding a few new touches...