Project 2006 Z4 - restoration (Enjoy!)

[andyfanshawe]

Here's a youtube video of the valvetronic motor removed from the car, connected to a 12V source and a waveform taken of the current it takes.
[youtube]RfUjN2Fl1TQ[/youtube]

Considering this is a precision motor, that waveform shows major inconsistencies between commutator segments. Time to order a good secondhand one. New ones from BMW are about 435 + vat. Ordered one at a cost of £38.

 

[andyfanshawe]

Quick update for everybody.

All photos relinked to a new server.

Replacement valvetronic motor fitted and car is perfect!

Been using it regularly over last few weeks and seriously enjoying it

BUT,....................one thing..................the clutch. Horrible. So, ordered an LUK Dual Mass Flywheel and clutch and will fit it starting monday evening. Shouldn't take long, and I will get plenty of photos.

Oh, price? £395 all in. Bargain.

Andy.

 

[sw4nny]

Andy,I am now starting to believe you are inventing some of these issues with the car just so you can repair and replace more things on this Zed,by the time your finished it will be a brand new vehicle. oke:

 

[andyfanshawe]

Andy,I am now starting to believe you are inventing some of these issues with the car just so you can repair and replace more things on this Zed,by the time your finished it will be a brand new vehicle. oke:

Ha ha! Yeah. Got me.

Look at my goodies:
Dual mass flywheel


Self adjusting clutch with fork


Friction plate


And rear main oil seal and spigot bearing


Oh, and self adjusting clutch fitting kit


Only got to fit them now.
Andy.

 

[Scooba_Steve]

Looking forward to a good how-to for this

 

[andyfanshawe]

Looking forward to a good how-to for this

Will do my best!
Will try to fit it in next week. 2 BMW's (not zeds) and a ford fusion to do before then!

Andy.

 

[Grumpyowl]

Hi Andy,
a few weeks have gone by since you reset my steering angle sensor or whatever it was you did.
Just to let you know everything is absolutely fine , couldn't be more pleased with the way the car steers, thank you.

 

[Steve84N]

What were your problems before it was reset?

My steering is constantly pulling to one side despite changing all the suspension parts and swapping tyres etc.

 

[Grumpyowl]

What were your problems before it was reset?

My steering is constantly pulling to one side despite changing all the suspension parts and swapping tyres etc.

A slight stiffness in the straight ahead position, meant I had to make a conscious movement either left or right.
Very annoying but it's all ok now very smooth and no notchiness or stiffness at all.
I was thinking about doing that centric ring adjustment but this has cured my problems

 

[andyfanshawe]

Hi Andy,
a few weeks have gone by since you reset my steering angle sensor or whatever it was you did.
Just to let you know everything is absolutely fine , couldn't be more pleased with the way the car steers, thank you.

Sweet!
Thanks for the update.
Andy.

 

[andyfanshawe]

What were your problems before it was reset?

My steering is constantly pulling to one side despite changing all the suspension parts and swapping tyres etc.

Hi Steve.
Whereabouts are you in the country? Anywhere close to J29 M1?

Andy.

 

[Steve84N]

Unfortunately not, I'm in Gloucestershire.

I've tried seeing how to reset the sensor using INPA but it only has the option for the e46. The only other thing I've used is NCS but not sure if that can do it...?

 

[andyfanshawe]

Clutch change then.......
Exhaust removal first. Here are rear box hanger bracket bolts. easy removal

Unbolted at the front (changing those nuts to brass worked wonders last year).
And out


Heat shields out, and propshaft out.. I had to temporarily remove the lower aluminium subframe bracket in this phototemporarily so I could get the prop out.







Clutch slave out (2 13 mm nuts) and wiring disconnected




Gear linkage next
Chrome rod first


Held on with these clips


Aluminium bracket off the gearbox next. 2 simple lever up and off clips




Tie wrapped it to the AC drain tube


Trans jack put under and trans lowered so I could get long extensions to the bolts






And gearbox out






First look at the clutch


and out




Not totally worn out, but old and tired (like me)


Dual mass flywheel in good shape, but its going anyway

44

The rear main oil seal is definitely leaking

BUT the oil pan is also leaking.....thats my next job then.





To be continued.......

 

[andyfanshawe]

How to get the spigot (pilot) bearing out of the back of the crank?

Stuff soaking paper through the centre until its full and hammer a good fitting rod through the centre.



Repack and repeat 2 or 3 times till it comes out



This is what is left in the hole

4

Tap new bearing in with 24mm socket



I didn't photograph the rear main seal going in, but I knocked a screwdriver through it and levered it out. Being very careful not to touch the crankshaft.

New DMF on with aligning tool inserted



friction plate in position



Pressure plate bolted on and centre spiral looking thing turned anticlockwise to remove it. If anyone was wondering, the LUK self adjusting clutches come already compressed. So no need for the expensive kit.

Didn't get a photo of the final assembly. but heres a photo showing the spiral looking thing in the centre that needs to come out once the pressure plate is bolted to the flywheel



Clutch fork and release bearing installed inside a cleaned up bellhousing


And all reassembled.

Not too bad a job really. 6 hours in total, taking my time. Book time is 3 and a half!!

Test drive next.

Andy.

 

[andyfanshawe]

One test drive later...........drives like a different car! So smooooth, no shuddering, juddering or stuttering! beautiful.
£436 of parts. Worth every penny. Was going to put it up for sale, but not sure now!! Driving time.

Andy.

 

[Grumpyowl]

The work you've done on it, it would be a shame not to get this summer out of it and sell next spring . :driving:

 

[idej_z4]

What an epic read this is! If I had put so much work into a car and got it running as well as yo u have there is no way I could sell it!

Keep it and get out and :driving:

 

[andyfanshawe]

And here we go again.................and a little test for BMW this time.!!

May 6th 2016. Ordered a new white LED third brake light from BMW - DIRECT on ebay. £61

Fitted it on 24th May 2016


Beautiful.

Fast forward to today and guess what?????



Yep, broken in half. And before someone says it was fitted incorrectly, the nuts were only finger tightened and slightly more.

Now theres a 48 month warranty on parts from BMW, so I sent a message to BMW - DIRECT on ebay asking them what the procedure is.

Their reply:
Hello,

Thank you for your message.

We are truly sorry to hear this and we would like to sincerely apologize for any inconvenience caused.

May we kindly ask you to provide us with images of the fault so we can proceed further with your query?

Thank you for your understanding and cooperation.

Kind regards,
George
BMW Direct

So I took loads of photos and 2 videos and put them on youtube and put all the links on a word document and popped it on dropbox and sent them the link

Heres one of the photos


[youtube]H6FyQqmGnn0[/youtube]

[youtube]S49VGEv3j54[/youtube]

Their reply:
Hello,

Thank you for your message.

We have sent your request to the relevant department and we will get back to you the minute we have a response.

Thank you for understanding.

Kind regards,
George
BMW Direct

Short time later....
Hello,

Thank you for your kind patience.

We have just been advised that all our parts come with a 2 year warranty.

As it is a car part and has been fitted it needs to be dealt with fitted parts warranty, this can be done by any BMW retailer.

Can you please book in the car with a retailer then take the car with the lamp fitted and proof of purchase, the claim with be dealt with accordingly at the retailer?

Thank you for your understanding and cooperation.

If we can be of any further assistance, please do not hesitate to contact us again.

Kind regards,
George
BMW Direct

 

[andyfanshawe]

Now its going to be REALLY difficult to refit it to the car now! Which should have been obvious if they had seen the photos. So, another message sent by me...

Do you honestly want me to refit it to the car??? Really??

Their response...

bmw_direct is out of the office until 17/09/2017 and may not be able to respond to your message.

Message from bmw_direct:
Hello,

Thank you very much for contacting us.
Unfortunately, our Customer Service Team will not be available to assist you with your query at this point in time. You can rest assured that we will endeavor to respond to all messages as soon as we can, upon our return on Monday.

Thank you for your patience!

Kind Regards,
Customer Service Team

The time was 4:43 pm.

 

[MACK]

Exactly the response I got. In the end I got them to send me another one but it was a bit of a fight.