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Unintended Project thread (better late than never!) - 2003 2.5i Auto

2003 - 2009, roadster, coupe, facelift
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Unintended Project thread (better late than never!) - 2003 2.5i Auto

Post by Rossi1001 » Sun Apr 07, 2024 1:23 am

So, I was posting a lot in another thread talking about 18 months of Z4 ownership, the history of the car, what's been going on in my life etc and I figured I probably should actually just do a 'project' type thread, rather than posting piecemeal here, there and everywhere! At 74 posts in now on this forum, I'm probably a bit late to the party on this, but better late than never right?

So the car is a Z4 2.5 auto (March 2003 build date car) in Titan Silver with red leather and it's not an M Sport. I believe that build date makes it one of the very earliest cars, as according to Wikipedia, they were not launched in Europe until March 2003.

It's done 97k miles and only 6k miles in the past 5 years (with 4k of those miles being from myself in the over the last year and a half). There are two working remote keys.

I bought it in August 2022 off a retired policeman who'd only had it for just over a year. He bought it with no prior service history (brave!), though did say the previous owner had owned the car for circa 7 years, which checked out when you look at the HPI history and when the personal plates were added / removed. It's had a high number of owners though, I am the 11th(!!), though I'm only the third owner in the past 10 years, so it changed hands a lot early in its life.

The chap I'd bought it from had spent about £1,500 on a full service, and some ABS issues plus works to the brake lines and had paperwork to back that up. At the time I thought he seemed fairly honest, but with the benefit of hindsight, I think he knew the car needed more work (and leaked in the rain!) and either he'd had enough, or his wife had told him to get rid of it!

So, what's gone wrong with it and what have I done to it? I'd recommend getting a cup of tea at this point before reading on, as this is rather long!
  • Intermittent non starting issue. After much head scratching (and a new battery it turned out I didn't need), the Green Flag man was about to recover it on his truck and it suddenly turned over in neutral (it's an Auto). Turned the key all the way and it fired up. The automatic gearbox was not selecting Park properly. I had a gearbox service done and the oil was like marmite / treacle and thankfully this has cured that problem. Changed twice though in 3x months (expensive!) as without going to a gearbox specialist there is no way to drain the oil out of the torque converter.
  • Parking sensors. It was just unplugged apparently according to my local mechanic, though two days later they stopped working again. He wants another £100 to take the bumper off again so I'll do it myself at some point.
  • The Alarm. This still goes off randomly at times, though keeping the battery topped up seems to resolve it weirdly.
  • Oil leaks. I've learnt from every mechanic that it's a common BMW problem apparently! It was leaking pretty badly from the valve cover and oil filter housing gaskets. Oil filter housing is now perfect, but the valve cover gasket is leaking again but in a different place. I'm going to look at this soon with the help of enuff_zed, as clearly my local independent didn't do something right!
  • Water leaks. I had a wet passenger footwell for some time. This turned out to be the passenger door membrane, where stupidly I initially used just double sided tape after repairing the window regulator cable. Do not do this! Use the proper butyl tape or some other form of decent sticky sealant!
  • Window regulator. The passenger side cable snapped. I used a cable repair kit to save some cash but I'd really not recommend going down this route. It's an absolute sod of a job, just buy a new or used regulator, it's easier!
  • Violent limp mode / lack of power. There is a long thread on this here, but in summary this was a failure of the original 21 year old MAF and a very badly split (and bodged with electrical tape! :headbang: ) air intake boot.
  • Cracked (both!) exhaust manifolds. To be fair this one wasn't the cars fault! I hit something in the road at 70mph on the M11 and whatever it was smashed into the where the exhaust manifold joins the mid section. £600 later and this has been repaired via welding, though this in turn knackered a post cat o2 sensor, which is partly why the total bill is so high, as it had to go back for that.
Stuff done to the car (fixes related to the above and preventative maintenance):
- Further full service and Auxiliary belts changed along with air and cabin filters
- Gearbox oil service - oil replaced twice over a 3 month period
- Valve cover gaskets replaced (inc screws)
- Oil filter housing gasket replaced
- New Battery
- 2x front shock absorbers replaced
- Replaced 4x tyres with Bridgestones (not run flat - so much better!)
- Replaced the broken passenger window regulator cable
- Replaced passenger door weather seal (this had been causing a leak - now fixed)
- Replaced the front inner steering rack joints (which came up on the last MOT)
- Replaced the MAF sensor
- Replaced the rubber air intake boot
- Exhaust manifold welded and new gaskets / nuts between front and mid exhaust section
- Replaced broken o2 sensor (following damage from welding above)
- Replaced a broken oil level sensor

Stuff already done to the car (out of choice / to improve it):
- Retrofitted cruise control (brand new stalk)
- Retrofitted cupholders with the correct SUPER RARE grey faceplates (thanks again Enuff_Zed!)
- Retrofitted LED interior lighting (footwells and boot light too - much brighter, more modern and uses less power)
- Replaced the rear centre brake light (OEM red original)
- Replaced both boot struts
- Replaced the hazard warning / door lock switched (original was very scratched)
- Replaced the front lower suspension arms, bushes and links (this along with new tyres significantly improved the handling)
- Replaced the ashtray unit (the moving lid was broken)
- Replaced the xenon headlight bulbs
- Replaced the engine and transmission mounts to cure a bit of engine vibration. This made the car feel SO much better!
- Replaced the gear selector surround (with a used, but better than my existing one from eBay). I'll have a go at painting the old one in an attempt to make it look like new at some point.

The current list of jobs (still to do):
- Roof motor relocate and some coding (I'm off to see Enuff_zed next weekend) :D :driving:
- Fix an intermittent cylinder 2 misfire (hopefully just a coil pack)
- Fit new aux in cable (bought from this forum)
- Fit new interior door handles
- Replace stuck rear eccentric bolts (so rear wheels can be aligned)
- Fix the valve cover gasket oil leak (again!)
- Diagnose and fix the rear heated screen (heated mirrors do work)
- Fix the parking sensors
- Fix the sodding interior rattles!
- Do a scuttle drain clear / flush and replace the broken scuttle clips
- Seats out proper carpet clean with a vax type wet hoover
- Some rear suspension / subframe surface rust removal and protection
- Install new door speakers*

"Maybe" jobs for the future (if I keep it long term)
- *I've got a full set of the Carver DSP speakers, though I'd still need the amp / boot wiring loom and subwoofer brackets / grills (plus a forum members help!) to fit these. As it's an early car, the door speaker wiring is already in place. So the stop gap to improve things a bit, is to just put in the door speakers for now, with the hifi loom left alone, and the wiring spliced off the tweeters (for now) for these.
- Swap my electric (but annoyingly not heated!) seats for some heated ones
- Do the top hifi retrofit
- Do a full rear suspension refresh / potentially replace or repair (shotblast etc) the rear subframe (need a lottery win for this one!)

So why the 'unintended' title? Well I certainly hadn't planned to be doing this much by way of fixes / improvements on this car when I bought it! To be honest I don't really want to total the money spent on it, as I'm pretty sure I've easily spent the purchase price of £3,700 on it again at this point! The car has certainly tested my patience at times. Towards the back of last year / early this year after all the limp mode and then the exhaust problems (plus other family health issues), I was getting a bit sick of the car and had I not already invested so much in it, I probably would have considered breaking it for parts. But now it's back up and running I'm really enjoying it again. I'm meeting up with Enuff_zed soon, I'm hoping to get a bit more confidence around doing work on the car myself. I know it will seem daft to many on here, but I was really pleased with myself for being able to fix the air intake issue as a complete novice!

The jobs left to do though are all relatively minor, so I'm hoping that I can now have a good summer out of the car without any major problems.

Pictures to follow!
Last edited by Rossi1001 on Sun Apr 07, 2024 2:20 am, edited 4 times in total.
Z4 2.5i Auto (April 2003, Titan Silver & Red Leather)

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Unintended Project thread (better late than never!) - 2003 2.5i Auto

Post by Rossi1001 » Sun Apr 07, 2024 1:40 am

So these are from August 2022 and taken by the chap that did a polish and headlight restoration for me. It's long overdue both again now sadly!

I'll take some interior pictures soon. As it's an early car, it has the grey interior (grey carpets, and grey dash and footwell plastics, vents, plus a grey leather gear selector and grey leather selector boot). From late 2004, the grey interior was binned, so some parts are an absolute nightmare to find as a result!
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Z4 2.5i Auto (April 2003, Titan Silver & Red Leather)

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Unintended Project thread (better late than never!) - 2003 2.5i Auto

Post by enuff_zed » Sun Apr 07, 2024 7:03 am

Great write up Ross. Looking forward to finally meeting you next weekend.
Not quite sure how much of that lot we can get done, so bring a list. Some we can tick off and others you can take notes and possibly get a bit more sorted yourself. Or come back again.
You’ve hit that catch 22 dilemma where you’ve spent so much you almost have to keep it! But I’m sure a summer of roof down motoring will make it seem worthwhile.
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Unintended Project thread (better late than never!) - 2003 2.5i Auto

Post by paddy wright » Sun Apr 07, 2024 9:53 am

Looks a lovely wee Z- glad it’s mostly sorted for you now.
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Unintended Project thread (better late than never!) - 2003 2.5i Auto

Post by Rossi1001 » Sun Apr 07, 2024 11:44 am

enuff_zed wrote: Sun Apr 07, 2024 7:03 am Great write up Ross. Looking forward to finally meeting you next weekend.
Not quite sure how much of that lot we can get done, so bring a list. Some we can tick off and others you can take notes and possibly get a bit more sorted yourself. Or come back again.
You’ve hit that catch 22 dilemma where you’ve spent so much you almost have to keep it! But I’m sure a summer of roof down motoring will make it seem worthwhile.
I think I might need a second visit! Looking forward to meeting you too, you've already done so much for me remotely (along with helping many others on this forum). Special shout out to bigwinn too, who's also given me a lot of help!

I'll be keeping it certainly for this year, though I think if I wanted a really long term Zed I'd want a 3.0 and a manual box. We'll see!
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Unintended Project thread (better late than never!) - 2003 2.5i Auto

Post by Usel » Sun Apr 07, 2024 6:44 pm

If you do visit Enuff_zed again and want some heated, electric red standard seats then pm me about a month before you plan to see him :thumbsup:

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Unintended Project thread (better late than never!) - 2003 2.5i Auto

Post by Mr Tidy » Sun Apr 07, 2024 8:38 pm

It sounds like you've had an unlucky run of problems, but it is 20 years old now so things are going to crop up and it sounds like you like it enough to keep getting it fixed!

My daily is a 2005 3 Series and in the 5 years I've had it I've probably spent as much keeping it serviced and broken bits replaced as I paid for it. But I figure that's OK because it isn't depreciating, and there's nothing I'd want to replace it that wouldn't cost thousands more!
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Unintended Project thread (better late than never!) - 2003 2.5i Auto

Post by Rossi1001 » Sun Apr 07, 2024 10:01 pm

Mr Tidy wrote: Sun Apr 07, 2024 8:38 pm It sounds like you've had an unlucky run of problems, but it is 20 years old now so things are going to crop up and it sounds like you like it enough to keep getting it fixed!

My daily is a 2005 3 Series and in the 5 years I've had it I've probably spent as much keeping it serviced and broken bits replaced as I paid for it. But I figure that's OK because it isn't depreciating, and there's nothing I'd want to replace it that wouldn't cost thousands more!
I agree, I've maybe been a bit unlucky, though some of the problems listed above were previous owner neglect (gearbox oil and air intake bodge), though much of it is just age, the car is now 21 years and 1 month old! The leak from the door membrane was just my own stupidity to be fair and the exhaust was just bad luck hitting something in the road. I can't blame the car for that one!
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Unintended Project thread (better late than never!) - 2003 2.5i Auto

Post by Rossi1001 » Sun Apr 07, 2024 10:02 pm

Usel wrote: Sun Apr 07, 2024 6:44 pm If you do visit Enuff_zed again and want some heated, electric red standard seats then pm me about a month before you plan to see him :thumbsup:
Ooh now I'm intrigued! I'll send you a PM!
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Unintended Project thread (better late than never!) - 2003 2.5i Auto

Post by enuff_zed » Sun Apr 07, 2024 10:27 pm

Rossi1001 wrote: Sun Apr 07, 2024 10:02 pm
Usel wrote: Sun Apr 07, 2024 6:44 pm If you do visit Enuff_zed again and want some heated, electric red standard seats then pm me about a month before you plan to see him :thumbsup:
Ooh now I'm intrigued! I'll send you a PM!
Rob is only up the road. Maybe he can drop in on Sunday for a chat
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Unintended Project thread (better late than never!) - 2003 2.5i Auto

Post by Rossi1001 » Mon Apr 08, 2024 1:10 am

enuff_zed wrote: Sun Apr 07, 2024 10:27 pm
Rossi1001 wrote: Sun Apr 07, 2024 10:02 pm
Usel wrote: Sun Apr 07, 2024 6:44 pm If you do visit Enuff_zed again and want some heated, electric red standard seats then pm me about a month before you plan to see him :thumbsup:
Ooh now I'm intrigued! I'll send you a PM!
Rob is only up the road. Maybe he can drop in on Sunday for a chat
I may have just signed up for a heated seat upgrade :D
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Unintended Project thread (better late than never!) - 2003 2.5i Auto

Post by enuff_zed » Mon Apr 08, 2024 6:21 am

Rossi1001 wrote: Mon Apr 08, 2024 1:10 am
enuff_zed wrote: Sun Apr 07, 2024 10:27 pm
Rossi1001 wrote: Sun Apr 07, 2024 10:02 pm Ooh now I'm intrigued! I'll send you a PM!
Rob is only up the road. Maybe he can drop in on Sunday for a chat
I may have just signed up for a heated seat upgrade :D
Plug and play on your car. Looms are in place, just need seats and switch panel.
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Unintended Project thread (better late than never!) - 2003 2.5i Auto

Post by Rossi1001 » Sun Apr 21, 2024 11:58 pm

So I was lucky enought to meet the wonderful Martin (enuff_zed) last Sunday (14th) and we (well very much mostly Martin!) got quite a few jobs done including;

- Roof motor succesfully relocated. It turned out the roof motor has been replaced before on this car, probably within the past 5 years. There was no drain blockage, however the sealed plastic unit was full of water, so it had obviously flooded at some point. I'm glad I didn't put this off longer as the motor would have failed eventually if left. Now I understand the mechanics of it better, the original BMW design just seems absolutely nuts. What were they thinking!?
- Coding (roof now works off the key, I now have a one touch passenger window and the car makes a satisfying beep and indicator flash when being locked / unlocked).
- Fixed an intermittent cylinder 2 misfire (this was pretty easy, the cylinder 2 coil pack just wasnt sat correctly :rofl: )
- Fitting a new aux in cable (bought from this forum)
- Fitting new interior door handles

Although we had the door cards off for the handles, we parked the door speakers, as I'd forgotten to order the blue connectors that go into the speakers prior to the visit. Also, it was the first time I'd had the drivers side door card off and the door membrane has seen better days, so we'll save this for visit number two when I've got a shiny new door membrane ready to go.

Stupidly, I didn't bring an aux in connector with me, so we couldn't test it at the time, but the radio couldn't find the aux input once I got home, so I need to pull this back out and have a second look at it. It's an official BMW bit of kit and seemed to only plug into one place, so I'm at a bit of of a loss on this one.

We pulled out an 'XCarLink' bluetooth / ipod and aux in box in the process of doing this. I thought this bit of kit was pretty ancient, but it's still sold new for £83 here plus another £40 on top for the bluetooth dongle. Although I could connect my phone up to this, the sound quality for music via the bluetooth wasn't great in my opinion, compared to the quality of sound through a strong FM signal (e.g. Radio 1), plus the dongle dangling underneath the climate controls used to annoy me, so I'm still going to persevere with the aux in option above. Longer term, I plan to buy a CarPuride dash top unit, which will just go straight into the aux input.

So jobs still to do are as follows;
- Fix the valve cover gasket oil leak (again! Didn't want to risk this last Sunday without a spare at the ready)
- Replace stuck rear eccentric bolts (so rear wheels can be aligned)
- Diagnose and fix the rear heated screen (the fuses are OK, as are the wires to the screen, so this could be a fusebox out, relays job, any ideas welcome here. The heated mirrors both work fine).
- Fix the parking sensors
- Fix the sodding interior rattles!
- Do a scuttle drain clear / flush and replace the broken scuttle clips
- Some rear suspension / subframe surface rust removal and protection - This might need to be a third visit, and I'll look at options for hiring a set of ramps for a day / half day to make this a lot easier. There are a few places around the country that offer this.

Plus some new ones not listed before.....
- A long 2 hour drive really confirmed that the steering is twitchy as hell (and not pleasant) at 60-65mph plus, so further investigation here
- The vanos probably does need a refresh in the relatively near future
- Disks and Pads and possbly one caliper is sticking

I'm also going to work with Usel (Rob) nearby to upgrade my seats to heated ones and refresh the leather at the same time, so for trip number two, I plan to leave the car with Martin / Rob for however long they need it so the time pressure is off, though stuff like the brakes, valve cover gasket and scuttle removal / drain clearance is something I'd like to learn to improve my abilities, so I'll do some bits whilst I'm there.
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Unintended Project thread (better late than never!) - 2003 2.5i Auto

Post by enuff_zed » Mon Apr 22, 2024 8:12 am

We got a fair bit done.
Hopefully the aux just needs pushing in a bit tighter.
I’ll get back with rough idea of prices for discs and pads etc
In the meantime I have found enough clips etc and fully repaired a scuttle panel so we can do a straight swap over.
Trouble with doing the eccentric bolts at mine is ideally you need alignment done, but I can get them close enough to not be a problem.
May be worth seeing if anywhere close to you would do an alignment and also clean up the rusty bits while it’s on their ramp?
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Unintended Project thread (better late than never!) - 2003 2.5i Auto

Post by enuff_zed » Mon Apr 22, 2024 8:14 am

Could do with some advice on the heated rear screen please.
Fuses are good and the connections are firmly fitted to the screen.
I can see one relay on the back of the fuse box but the second one is inside the box! Can this be accessed at all?
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