Z3 M Coupé Resto and Engine Rebuild !
 

Hey everyone,

In the brief time I spent on this site, I realized that most of you are not only CSL fans but also general ///M car lovers, just like me. So I thought I could share my little restoration projects of my other ///M cars for others to hopefully enjoy.

This is the restoration of my '00 M Coupé which I acquired almost two years ago ;

The car was turbo'ed by the PO which I admit was part of the charm for me although I am a die hard NA man. I just wanted something different then my old Dakar Yellow M Coupé (Gone). But after a few months of ownership the novelty of Turbo setup wore off and I missed the driving characteristics of a strong NA engine.
So , I have started work on reversing the car to NA and doing other bits and mods along the way.

I had a similar thread for my Dakar MC last year which was fun to create, here it is,

Dakar MC Restoration From Turkey

I know many of us like these build threads so I decided create another one for the new ride.

Here is a list of things we did first,

-Turbo Kit taken out
-Extra Gauges and control units (EVC,AFR DEFI etc.) taken out
-Engine Cover stripped of cheesy paint theme
-All the fluids replaced (TWS for Engine, FM Booster for Diff, SRT for brakes and OEM Trans Fluid)
-Alu look door trim installed ( To match the exterior color )
-New Floor mats put and leather bordered
-Custom Pedal Set designed and installed
-Engine taken out for NA rebuild and stripped of boy racer paint
-Hamann Roof wing replaced with ACS piece.
-Replaced painted grills with OEM chrome parts.
-OEM Short Roof Antenna put in.

What is next ?

-Full NA engine rebuild
-CF Airbox
-Repainting every engine part to stock colors
-Polishing stock headers before install
-Removing Hamann Side Skirts and maybe rear side diffusers ?
-Leather reconditioning of the interior
-Adding red stitching to door grabs and center console L pieces
-Replacing aftermarket headunit and cd changer with OEM parts
-ECU tune to run the airbox
-Replacing worn BBS center caps with new ones.
-Major detailing including underbody to finish everything off.

and as always taking care of little surprises and hiccups along the way :)

So, lets begin,

This is her, aka " Junior " the day I bought her with po's plates,

http://i593.photobucket.com/albums/t...3/fotoraf4.jpg

First things first, we replaced all fluids, (TWS for Engine, FM Booster for Diff, SRT for brakes and OEM Trans Fluid)
Old Diff oil. This so called lifetime oil was literally black,

http://i593.photobucket.com/albums/t...13/image11.jpg

http://i593.photobucket.com/albums/t...13/image12.jpg

New OEM Diff Oil with FM Booster put in ($$$$!)

http://i593.photobucket.com/albums/t...13/image13.jpg

Before moving in to engine rebuild, I made some cosmetic enhancements,
Replaced the black door trims with alu look trim to give a little contrast to the cabin and reflect the exterior color.

Before,

http://i593.photobucket.com/albums/t...13/image16.jpg

After,

http://i593.photobucket.com/albums/t...13/image17.jpg

Then got some new floor mats and leather bordered them in red to highlight them a bit, ( You can almost see the boy racer gauges on center console )

http://i593.photobucket.com/albums/t...13/image19.jpg

http://i593.photobucket.com/albums/t...13/image18.jpg

Then replaced the Hamann pedal set with custom pedals made specifcly for my car by www.bmwpedals.com

Hamann set before,

http://i593.photobucket.com/albums/t...13/image20.jpg

Custom Set,

http://i593.photobucket.com/albums/t...13/image32.jpg

http://i593.photobucket.com/albums/t...13/image34.jpg

http://i593.photobucket.com/albums/t...13/image36.jpg

Last thing for the interior was to remove the turbo control units and replacing the ashtray,

before,

http://i593.photobucket.com/albums/t...urkeyZ3M56.jpg

after,

http://i593.photobucket.com/albums/t...13/image27.jpg

Very nice Clubber :thumbs:

Always loved these, just a pity I can't even fit in the drivers seat, never mind drive one :(

Thanks my friend. I admit they are a tight fit but well worth it :)

And then I moved to the engine. How the engine looked when I got it. With lots of custom paint and F&F colored hoses and etc..

http://i593.photobucket.com/albums/t...urkeyZ3M33.jpg

http://i593.photobucket.com/albums/t...013/image7.jpg

And then the engine came out for the rebuild,

http://i593.photobucket.com/albums/t...13/image37.jpg

http://i593.photobucket.com/albums/t...13/image38.jpg

First I wanted to attend to the engine cover. Removing the old paint and preparing for repaint to OEM black.

Used a fair bit of paint remover,

http://i593.photobucket.com/albums/t...13/image21.jpg

Paint remover working its magic,

http://i593.photobucket.com/albums/t...13/image22.jpg

Lots of scrubbing with sand paper and wire brush,

http://i593.photobucket.com/albums/t...13/image23.jpg

Almost there,

http://i593.photobucket.com/albums/t...13/image24.jpg

Then I let it cool down a bit and moved to the engine block for the same process,

Terrible red theme :(

http://i593.photobucket.com/albums/t...13/image41.jpg

http://i593.photobucket.com/albums/t...13/image46.jpg

Paint remover applied,

http://i593.photobucket.com/albums/t...13/image47.jpg

Spray washed,

http://i593.photobucket.com/albums/t...13/image48.jpg

Almost there,

http://i593.photobucket.com/albums/t...13/image49.jpg

I'll have another go at it with gas and alcohol before the paint this weekend.

Super glad with the cleaning stuff, I set my sights on the throttle bodies. Since those are a little complicated to dismantle, I left the job to my mechanic and then I started.

Before,

http://i593.photobucket.com/albums/t...13/image44.jpg

Almost two hours of scrubbing, washing and brushing with various stuff,

http://i593.photobucket.com/albums/t...13/image45.jpg

I believe they turned out pretty good.

More to come...

:smt023

very nice project :smt039

Thank you guys.

After the clean up, I put the first coat of black paint on the block.

First I masked all the necessary areas and heated each side before paint,

http://i593.photobucket.com/albums/t...3/fotoraf2.jpg

Then the first coat of black was sprayed,

http://i593.photobucket.com/albums/t...3/fotoraf3.jpg

I want this paint to stick so I am taking my time with it.
I put the second and third coat of paint on the block and finally it looks clean and new.

http://i593.photobucket.com/albums/t...fotoraf2-1.jpg

Now that the block was ready, we started the rebuild. Piston and rods prepped,

http://i593.photobucket.com/albums/t...fotoraf3-1.jpg

First the crank went in,

http://i593.photobucket.com/albums/t...2013/crank.jpg
Then the pistons,

http://i593.photobucket.com/albums/t...fotoraf4-1.jpg

Done a bit more engine work,

Put on a new water pump and installed the oil filter housing after a thorough clean up,

http://i593.photobucket.com/albums/t...g?t=1358265397

http://i593.photobucket.com/albums/t...3/image2-2.jpg

Oil pan put back,

http://i593.photobucket.com/albums/t.../image32-1.jpg

New head gasket in,

http://i593.photobucket.com/albums/t...13/image52.jpg

Headgasket before cleaning,

http://i593.photobucket.com/albums/t...013/image4.jpg

http://i593.photobucket.com/albums/t...013/image5.jpg

and cleaned and installed,

http://i593.photobucket.com/albums/t...3/image2-1.jpg

http://i593.photobucket.com/albums/t.../image42-1.jpg

Almost there. Engine should be done by the weekend. Still looking for the headers, they are hard to find :(

M rebuild
 

Great work Clubber

:-D

Thanks.