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Sam's Project Clubsport/OEM+

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Mr Tidy
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Sam's Project Clubsport/OEM+

Post by Mr Tidy » Fri Jul 22, 2022 9:23 pm

LemonConnoisseur wrote: Fri Jul 22, 2022 8:52 pm Update time, not the battery...

Unfortunately it appears as though the starter motor has shat itself now! An unexpected job to be attempting tomorrow, just got to hope that Euros have it in stock and BMW have the bolts in stock.
Oh dear! With a bit of luck the motor might come with new bolts - I know the water pumps do.
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Sam's Project Clubsport/OEM+

Post by LemonConnoisseur » Fri Jul 22, 2022 9:40 pm

plenty wrote: Fri Jul 22, 2022 9:17 pm Love this kind of thread and this one is really well put together.

Not in way way questioning the results experienced but in theory at least a bigger front ARB without any other mods should actually increase not reduce understeer.
Thanks :)

Oh I absolutely agree, adding a bigger front ARB and doing nothing else should increase the understeer for sure. I genuinely don't know how this hasn't, but maybe it is all due to the -.5 degree of camber I managed to add in :trampoline:

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Sam's Project Clubsport/OEM+

Post by LemonConnoisseur » Fri Jul 22, 2022 9:41 pm

Mr Tidy wrote: Fri Jul 22, 2022 9:23 pm Oh dear! With a bit of luck the motor might come with new bolts - I know the water pumps do.
One can hope! Although, reading Lucas' thread/guide, he didn't change the bolts so I doubt they do come with them. We shall see tomorrow :)

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Post by plenty » Fri Jul 22, 2022 11:15 pm

LemonConnoisseur wrote: Fri Jul 22, 2022 9:40 pm Oh I absolutely agree, adding a bigger front ARB and doing nothing else should increase the understeer for sure. I genuinely don't know how this hasn't, but maybe it is all due to the -.5 degree of camber I managed to add in :trampoline:
That would certainly explain it!

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Post by LemonConnoisseur » Sat Jul 23, 2022 8:19 pm

So another update time, this is going to be a bit of a long one with a fair few pictures. So long that it'll likely spill over into a couple of posts, so bear with me.

As I mentioned before, the starter died yesterday at McDonald's. There weren't really any prior symptoms beforehand other than it being slightly sluggish to start yesterday afternoon, but it just felt like a slightly low battery. Anyway, I managed to secure a remanufactured Bosch unit from ECP this morning, which was a good start! That was quickly turned on it's head because calling BMW meant that I was going to have to wait until Monday to get the replacement starter bolts. Given they're aluminium and weigh about as much as a feather (they're unbelievably light), I didn't really want to risk snapping anything given the location - drilling them out would not be fun at all.
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I got home and decided to tackle the removal of it anyway, as I can then just fit the new starter in place with one of the bolts loosely secured, to then be swapped out once I've got the new bolts. Simple, right?

Having read Lucasxdiniz guide on his starter motor replacement, I was going in with confidence! This disappeared almost immediately. I don't know if it's because Lucas has the later model N52 with the different CCV system, or the fact he's some kind of Wizard, but I have no idea how he managed to remove it with the intake manifold in place.

Onwards and upwards, it's only an intake manifold, it can't be THAT hard.

Started with the removal of the top of the airbox and the sound generator. I later went back to remove the bottom portion of the airbox for space.
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Removed one side of the strut bar for access.
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Very carefully removed the CCV pipe that connects on to the rocker cover - I've read horror stories about how brittle this pipe is, so I really, really didn't want to break it. (Thankfully it looks intact at the moment)
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Dropped the throttle body off the intake (not sure if this is even necessary)
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Loosened all of the torx screws for the DISA Valve as I wanted to inspect it. Tried to give it a tug, it didn't move. Won't be inspecting that one then.

With that removed, I started to undo the bolts/nuts that secure the intake to the head. Simples.

Tried to give it a pull to see where was causing resistance and preventing me from removing it, discovered the fuel line that connects to the rail. Again, a scary fitting that could break, but being gentle it came off. Slightly covered in fuel, but we persist!
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Pull again, realise there's another CCV hose connected down below that's causing issues. Struggle to remove it, but off it comes.

At this point, I'd removed a fair amount of bits, and really didn't want to cock anything else up, so I decided just moving the intake to the side would hopefully give me the access I needed.

I could now see the starter in all it's glory! Still a bit awkward to get to, but managed to get both of the bolts out, plug disconnected, and the positive wire removed, with the only injury being a slightly bruised knuckle due to accidentally punching the side of the head whilst undoing one of the bolts. Success!
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Quickly checked the new starter against the old, as ECP had a couple of different fitment options, but I took a gamble and it paid off.
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Attachments
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Post by LemonConnoisseur » Sat Jul 23, 2022 8:50 pm

On a high from the success so far, as the intake was off and a usually difficult to access torx bolt was now basked in glorious light and ease of removal, I decided that it would be a smart idea to change the oil filter housing and oil cooler gaskets as I had meant to do them before but couldn't due to tool limitations. This is where everything started to go wrong. :rofl:

I'd read a couple of guides/watched a couple of YouTube videos beforehand to get an idea of what is involved. In videos, as is always the case, it doesn't look too difficult and everything comes off with ease! In reality, that really is not the case.

With the oil filter removed, it was time to begin.
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After removing one of the, usually, difficult to access bolts, I was feeling smug. Very smug. "Phwoar, with the intake off, this is gonna be a piece of piss!"
How foolish of me.

I could remove both of the upper torx bolts on the filter housing with no problem, placed them to one side. Tried to tug it, it moved a bit but felt as though it was stuck. It was only then that I remembered the infamous third bolt, that sits right next to a coolant flange. Bollocks.

I tried to get a spanner on it, no luck. Then tried a socket, no luck. Ok, so that coolant flange is going to have to come out. No issue, two 10mm bolts, a slight pull, and...
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For f**k sake.

Now, after doing some research in hindsight, I realise that these are a brittle piece of plastic that are known to fail. Lovely!
I was pretty deflated when this happened, but at least with it out I could now access the last bolt keeping the filter housing in place.
This proved to be a right little bastard to remove. I've never tried to remove a bolt with worse space than this, not a pleasant experience in the slightest!
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But, with that removed, it was free! Sort of.
My new E-spanners, although the correct size for the stupid bobble bolts, couldn't get any purchase on the one situated underneath the oil cooler. The 2 coolant pipes that connect to both the cooler and filter housing needed to be removed, which caused coolant to go absolutely everywhere - great. I then lifted the filter housing out, and as I should have anticipated, oil then went everywhere to join the coolant in the undertray/all over the driveway. Much blue roll required to try and catch any last drops that hadn't evacuated from the system, it was not very successful.
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With the filter housing and cooler now out, slight joy returned as I could now get to the last bolt! Also, judging by the state of both components, I'd say this has been leaking for a while.
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Gaskets have seen better days, too!
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New gaskets, Elring items. They came with the car which was handy.
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Attempted to give both parts a clean with Aldi's finest kitchen cleaner 8)
Better than it was before anyway. Also cleaned up the mating surfaces and fitted the cooler back onto the housing with some new bolts I got from BMW.
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Post by LemonConnoisseur » Sat Jul 23, 2022 9:02 pm

Cleaned the mating surface up on the head, then popped the cooler back on. Even though they're aluminium bolts, there's no instruction that they need to be changed for new, so just reused those.
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Went to attach the coolant pipes, and I came across an issue. If anyone can help with this, that would be wonderful...
Where the f**k is this O-ring meant to go?
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I figure the plastic piece sits in the coolant pipe itself and goes onto the tapered metal part of the pipe, but the O-ring is nowhere near the right size?

I've popped the coolant pipe back on without the O-ring, but can revisit it if it turns out it's necessary, or I've broken the coolant pipe; the latter would not surprise me at this stage.

Also, whilst looking in the boot for the other gaskets, I came across a Victor Reinz packet with 6 O shaped gaskets. Intake manifold perhaps? Yes :D

They probably didn't need changing, but as they were there, and the intake was in the state it was, on they went!
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And now that brings me up to date.

Next steps? Well, as I said, I've ordered the bolts to the local BMW dealer for Monday. I also managed to order a new coolant hose to replace the one with the broken flange. However... I have found an aluminium flange on Amazon. As the plastic version is a common fail point, and if I can avoid spending £60 on a new hose, I have ordered it. It should arrive tomorrow, so I will have a go at crushing the remainder of the plastic flange in the coolant pipe and pop the aluminium version in. Fingers crossed :)

Looking at the coolant that did fall out, I'd say it needs a change. I'm hoping I can get the starter buttoned up on Monday evening after work, Tuesday evening at the latest, then it should be all good to go! Famous last words.

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Post by Vanne » Mon Jul 25, 2022 10:26 am

Build it up and take it to unzed with ya.. then flog it off there for 3 x the profit. :) :thumbsup:
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Post by Beesza » Mon Jul 25, 2022 2:27 pm

I had to use lots of plumbers grease on that O-ring to get it back in. O-rings can swell over time.

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Post by LemonConnoisseur » Tue Aug 02, 2022 4:01 pm

Need to update this again properly now the starter has been replaced and I've done some other bits.

Did a Brands Hatch evening session last night. Car was faultless, but it's in need of some better brake pads and tyres for it to be quicker (not to mention the person behind the wheel :roll: ). Took some videos on a GoPro that I'll upload if they're any good.

What a track though! Paddock Hill and Clearways are pretty tricky to get right.

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Post by Barty » Tue Aug 02, 2022 4:09 pm

Nice job and great pics, I’ve got similar work planned shortly so your experiences have proven very helpful indeed! :thumbsup:
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Post by hopz121 » Sat Aug 06, 2022 10:39 pm

Great thread, I was very close to buying this car and planned to do exactly what you have done going down the OEM+ route so it’s great to see your progress. Nice one on the odd jobs and brake down fixing too. Should be a well sorted end by the time you have finished with it :)
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Post by LemonConnoisseur » Wed Aug 10, 2022 10:12 am

So, in a slightly disjointed manner, I will now update this to where the car sits now!

Following on from fitting the intake manifold gaskets, BMW came through with the goods, in the form of 2 new starter bolts and a new top radiator hose as I had figured something was broken due to that mysterious O-ring that wouldn't go back in it's home.
Also, whilst I was there, I decided to fit a new auxilliary belt and belt tensioner, as I'd dropped some coolant and oil on the belt and didn't fancy it slipping. Turns out the tensioner had been replaced (would've known this if I had actually read through the service history/invoices properly, but alas), but I had a new INA one anyway, so popped that on.
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I also replaced the brittle plastic coolant "Mickey-Mouse" flange with an aluminium version - some people would replace the whole hose, but it was in good condition with only the flange being broken, and on E36s a similar upgrade is carried out by replacing a plastic thermostat housing with an aluminium version meaning it doesn't crack. :)
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Good thing I did buy a new hose, this is the O-ring that had swelled.
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Popped the new bolts in the starter motor, then went through the process of reattaching everything. No real issues, and was very careful with the CCV pipes as I really didn't want them to break now.

Finished fitting everything up at about 10pm, then wanted to give it a start just to check that there was nothing wrong and I could go to bed happy.
Reconnected the battery terminals (loosely), went to start the car, ignition light on (good!), turn the key, complete darkness.

I'm there thinking "oh my God, what have I done? Have I wired the starter up wrong, shorted something and blown the ECU? Surely not..."
Cue me going to the engine bay, taking the fuse cover off, panicking that I'd blown something. Then I think, "maybe I should just check the terminals have a solid connection" - tighten up terminals, turn key, fires straight up :rofl: :rofl:
Lesson learnt!

Also, last mod of this session was fitting a new stubby aerial, as the last one had some strange metal/carbon fibre combo which I disliked.
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Drove around for a couple of weeks with no issues, I was happy with the work I'd carried out :)

Had a weekend trip to Shropshire booked for the girlfriend's birthday, so swung by a mate's workshop on the way to pop some new oil in, and change the filter. I think it had only done about 6000 miles since the last change, but it was about 12 months ago, and I had the track day booked so wanted to do it in preparation for that. Also changed the brake fluid for some ATE TYP200 because I was getting brake fade on the road and I really didn't want to boil the fluid on track. Whilst it was up in the air I wanted to remove the CDV (I didn't experience any of the kangarooing, but wanted to check) - took the line off, turns out it doesn't have one anyway, result :)
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Got to Shropshire, chilled for the first evening and went to dinner in Shrewsbury.

As we were so close to Wales, and I've been on some of the roads in the north, I wanted to venture across the border. Drove from the place we were staying to Devil's Bridge and enjoyed some of the roads on the way there! A lot of the limits are 50mph, and there are countless caravans, but managed to stretch the legs a couple of times anyway. The car is perfect for the Welsh countryside and made me extremely happy with my purchase.
Brake fluid was ideal too, no more fade!
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Last edited by LemonConnoisseur on Wed Aug 10, 2022 10:50 am, edited 1 time in total.

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Post by HGoward » Wed Aug 10, 2022 10:21 am

Fantastic write up, and its nice to see your giving it the treatment it deserves. It's unfortunate about the starter motor, I had never had any inkling that it was going just maybe one lumpy cold start a long time ago. The next thing on the list has surely got to be Scotland now, the roads are similar to Wales but instead of the roads only being say a couple miles you'll get 12 miles are driving heaven.
I have to say I extremely miss this car now as the M240 is just not the same. Very fast but it doesn't handle the same in the corners at all. But that's what I get for moving away from a designated sports car.
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Post by LemonConnoisseur » Wed Aug 10, 2022 10:35 am

HGoward wrote: Wed Aug 10, 2022 10:21 am Fantastic write up, and its nice to see your giving it the treatment it deserves. It's unfortunate about the starter motor, I had never had any inkling that it was going just maybe one lumpy cold start a long time ago. The next thing on the list has surely got to be Scotland now, the roads are similar to Wales but instead of the roads only being say a couple miles you'll get 12 miles are driving heaven.
I have to say I extremely miss this car now as the M240 is just not the same. Very fast but it doesn't handle the same in the corners at all. But that's what I get for moving away from a designated sports car.
Thanks Harry. Yeah, the starter came out of the blue, was fine one day, dead the next. But now happy another common failure is fixed :)

Scotland is on the list, probably going to be next year though. Don't particularly want to do it when the roads are wet (although this could always be the case being Scotland :roll: ), as I'd like to enjoy them properly.

They're very different cars, the driving experience of the Z4 is awesome - low, direct, enough power to have fun but not kill yourself.

If you decide the M240 isn't enough, I'm sure you could swap it for a Z4M :evil: :evil:

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