TiAg ZHP

[paulkeith]

so, I figured I'd throw together a thread of my work on my ZHP. The color is titanium silver, thus TiAg ZHP.

Any questions or comments welcome. holler!

Paul

[paulkeith]

Basics on the car:
2004 ZHP
Titanium Silver
Alcanatara, Black Cube, Sunroof, Cold Wx, Sirius, Bi-Xenons, HomeLink, HK
110,000 miles, Maintained with Old-School MX
Bone stock
Full records for all MX, window sticker too


Jason’s FS pics:








Flew up last Thursday night and met Jason Friday morning. We exchanged funds for title and went to the DMV. Jason was a good enough guy to stick around with me at the DMV for 2 hours to get the whole transaction completed. A set of temp tags and $20 to uncle Connecticut, I was on my way back to Atlanta.


I overnighted in Waynesboro, VA. Some of you may know; this is the city just to the west of the start of the Blue Ridge Parkway. I got up at 5:45 Saturday morning, ate my "buffet" breakfast and was on the Parkway by 6:30AM. What did this mean? Ghost town. Oh, and fog. A lot. Of. Fog.

















Mile Marker 60 (I got on at MM0):





Cruised the Parkway for 60 miles. Saw 4 other cars (all going the other direction), 5 deer, a turkey, and 8 cyclists….and that’s literally it. Perhaps not as much a “Driver’s” road as I expected, but simply stunning nevertheless. Glad I added it to the trip. Got back on 81 on the other side of Glasgow VA and made my way to Atlanta…with a quick stop at the Zentrum. :biggrin :








All in all, put exactly 1,000 miles on the car. Clicked over 1,000 literally as I pulled into my subdivision. The car was a blast. So smooth, quiet, strong, nimble; basically a fantastic cocktail of sport blended with lux. This is what I read about the ZHP, what made me dead set on owning one, and I’m glad it has turned out to be true.


I’d like this thread to serve as a logbook for my work on the car, including maintenance, mild mods, and hopefully give some experience back to the ZHP Mafia community. I’m a pretty handy DIYer and hopefully I can document my work well enough to give some knowledge back this forum that has already helped me a great deal.


To start off the repairs and mods (a very quick and dirty bit on each):


Idle Stumble: The car developed a slight stumble when revving off of idle in the last 20 or 30 miles of the trip. Ambient temps were in the high 90s with humidity in the 80s and the car had been heat soaked for hours – not that this should ever matter. I replaced the very dirty and grimy K&N filter with a paper Purolator (for now) and used MAF cleaner on the MAF. So far so good. Will likely stick with paper but move to a Mahle when I get a chance to place my first big Pelican Parts order.


Aux Input: Bought BMW’s aux input. Took me maybe 15 minutes to install. Pop the glovebox trim off (with plastic trim tool to avoid marring), then the radio trim. 2 Phillip’s screws, pop the radio out. Remove the connector at the rear, slide out the blue retaining clip, and add the aux input connector. Route the cable to the spot of your choice; I went with the upper right corner of the middle console bin. Still need to pick up a 3.5mm M/M cord. Once connected, the radio automatically adds the source to your “Mode” list; I now have AM/FM, Disc, Disc Changer, Sirius, AUX.


Shift Knob: Replaced the worn original knob with another OEM ZHP knob. What else? This is the best knob on the market, bar none. Am considering a rebuild of the linkage; it’s a bit sloppy.


Posts/work to come soon:
Lighting: Original ZKW 2003 build year driver’s Xenon has zero light output. It turns on, but looks like a cataract. Replacement OEM ZKW 2005 build year Pax light has orange glow at periphery of output pattern. Suspected & confirmed severely burned bowls on both. Hopefully this is the extent of the problem. Solution has shipped, I will document all my work and post it up here.


Exterior Trim: Ordered replacement front bumper center moulding. GA requires no front plate; I ordered a plain and also a Euro plate strip. I was born in Germany and spent several years of my life living there, so I might rock a German plate as a bit of a throwback. Can’t decide if I want a Munich plate as homage to BMW, or perhaps my family’s hometown as something more personal. I’m going to go with the plain center moulding until I make up my mind.


Exterior Trim: Ordered Khoalty black kidneys. The original chrome kidneys are cracked and barely hanging on. Going to try the flat black look.


MX: Expansion tank, belts, idlers ASAP. Rest as per OSM.




Also got a new BMWCCA membership and joined the ZHPMafia SIG too.


Anyway, sorry for the marathon! Hope yall enjoy - I’m looking forward to getting to know everyone around here better.


-Paul

[paulkeith]

This afternoon I picked up a handful of detail products. I've tried a couple different products here and there with the Ms and 325, so I picked and chose and also took some recommendations from paint correction threads here and on E46F.


What I picked up today from AutoGeek and Detailer's Domain:


Hands off first rinse:
Autogeek's Quart Foammaster Foam Gun
DP Xtreme Foam Formula Auto Shampoo


Hands on second wash:
lambswool mitt
P21S Bodywork Conditioning Shampoo


Wheels:
SONAX Wheel Cleaner
Daytona Speed Master Wheel Brush
Clean Wheel Lug Nut Brush


Drying:
P21S Drying Towel


Interior:
Carrand 2 in 1 Electrostatic Detail Brush
303 (what else)


Engine compartment:
Adam's All Purpose
Couple brushes


Glass:
Stoner's


Plus a few microfibers, towels, etc.


As far as polishes/sealants/glazes/waxes go, haven't made up my mind yet. I'm leaning towards Klasse AIO, Klasse Glaze, and P21S Carnuba as a final step. Used zymol, mothers, and meguiars products in the past and never really had any complaints. This paint is in pretty good shape for my standards and uses (and was maintained yearly with Klasse) so Klasse and P21S should probably do the trick for at least some time.

[paulkeith]

Big update!


So I pulled both headlights apart. I found both xenon bulbs to be quite cloudy, driver’s being the worst:





I also found that my driver’s bowl was indeed burned (right) but the passenger bowl was actually still in perfect shape (for now anyway):












I did a lot of reading on all of the possible solutions, including just putting new ZKW bowls back in, swapping to AL assemblies and buying the 3-wire bixenon controllers, doing a lightwerkz retrofit, on and on, and finally stumbled across a guy on E46F, member “fgin,” who claimed that E90 projectors were a 90% plug and play kind of swap, minimal drilling, no JB welding, etc. ZKW got their head out of the sand and made the e90 bowls out of metal. They also use an identical in function and design bixenon solenoid with connectors that accept the E46 wiring. E90 projectors pop up on ebay for about $30 without bulbs, so this sounded like it was worth a shot. Ordered two for $70 shipped.


How they arrive (along with my headlight and the tools I needed):





First you have to unbolt the adaptive lightning motor:





Then drive the adaptive lighting hinge pins out with a long thin screwdriver + hammer:





Unscrew the two screws holding the bixenon shutter on, then use a thin screwdriver to separate the bixenon shutter from the bixenon shutter solenoid actuator pin:











Using a thin screwdriver, lift the retaining tab on both sides of the bixenon solenoid, and slide it off of its tracks:








Remove the last 4 torx screws holding in the bowl:





Now you’re down to just the plastic frame, which is ready for you to modify as needed:





At this point, I’ll have to use some of fgin’s pics. I didn’t take pictures as I worked through driver’s side as I planned to do all the pictures on the passenger assembly. When I got my passenger OEM bowl out to find it wasn’t burned, I had already assembled the drivers’. So here are pics of where the plastic frame needs to be modified (3 holes drilled, adaptive arm cut off, few other trimmings), all credit to fgin on E46F (his link here: http://www.e46fanatics.com/forum/sho...d.php?t=845704)





Once you’ve completed those mods, the basket will hold the bowl and attach to your projector lens perfectly. The only remaining issue is that the E90 projectors use D1S bulbs whereas E46s use D2S bulbs. To remedy this issue, you have to modify the bulb holder (piece of bent wire). The bulb sits in the socket fine. Fgin’s design used some screws which I didn’t like. I wanted it to be 100% removable by hand. I spent a solid 1.5 to 2 hours farting around with this wire, but eventually bent up a shape that retained the D2S bulb in the D1S socket very solidly (let's see if someone can spot the cap from the medicine i needed to stay calm while bending this stupid wire) :











Reassemble all and here is the pattern you get:





Note that the mirror smooth reflector design of the e90 (driver’s) has a much smoother light output pattern from the center of the output down whereas the angled reflector bowl of the e46 ZKW (passenger) produces noticeable patterns in the light below center. They’re not a 100% match, but I don’t care. These are like daylight compared to what I had before.


I actually realized when my passenger headlight was out that the bixenon solenoid was pretty rough in movement and feeling, so I replaced it with the smooth feeling unit from my now-junk driver’s bowl.


I’ve filled both lights with 4300K replacement bulbs from Khoalty. I plan to order some Philips 4300K at some point as the bulbs from Khoalty are no-name Chinese bulbs, I question their reliability and don’t want it as an asterisk in my head down the line. I also spent a good bit of time polishing both the bowls and lenses with a microfiber. Both shined up quite a bit, the lenses especially were just plain dirty.


So there you go. For $70 for two E90 projector assys, and about 3 hours of fiddling with drill bits, torx drivers, and pliers, you can remedy the ZKW bowl flaw permanently with all OEM parts, retain bixenons, no JB weld and no codes. Do it.


Paul

[paulkeith]

I bought black kidney grills from Khoalty as the stock kidneys were cracked and rattling.





I also bought the OEM bumper trim filler to replace the front plate bracket. I picked up the euro plate bracket as well so I can run a plate when I figure out what I want to get.





Before:





Plate filler (before cleaning dirt off bumper):





Black kidneys:





Very happy with the cosmetic improvement of the front end.

[paulkeith]

I put the entire mx history plus all paperwork for the ZHP into protective sleeves in a 3 ring binder:





My hardback bentley (didn't realize it was a hardback as i ordered it....woops):





Mad goodies:





Sonax at work:



First attempt at a foam gun ever, still messing with the settings. For $59 it's tough to beat:





Soaked with Adam's All Purpose and agitated with a brush:











Rinsed (and underhood insulation removed to dry, check out the discolored spot):














Followed this all with a handwash with lambswool and P21S. Dried with an Absorber.


All done:














The astute will note that my passenger headlight is out in this picture. that's because, I, in my infinite wisdom, left the rear dustcover off my headlight when I reinstalled in. Washing the engine compartment got a ton of water in there. DOH! I took it back out and set it in the sun to dry before I fire it back up.


By the way, Adam's All Purpose ROCKS. One of the best car products I've used in a long time. Many thanks to Detailer's Domain for posting its effectiveness here on ZHP Mafia and the link to purchase it. I'll be back for more, that's for sure.


Anyway, there's my slew of updates. Enjoy the pics, ask questions, leave comments.


Later!
Paul

[paulkeith]

So...now that most of the immediate issues have been addressed, I got one last big parts order put in. This should have me set until 120 or 125k when I do an inspection II


- Upper & Lower Hoses
- Expansion Tank
- Air Filter x2
- Oil Filter x2
- Fuel Filter
- Activated Carbon Cabin Filter
- 14 QTs 5W30 BMW Synth
- 2 Gal BMW Antifreeze
- Hydraulic Tensioner
- Water/PS/Alt Belt
- Tensioner Pulley
- Idler Pulley
- A/C Belt
- Wiper Blade Refills
- Valve cover bolt trim caps
- New stud + washer + nut for 1 valve cover bolt that I found cross threaded
- shift bushing, new washers, and circlips. -- I hope I can tighten up the stock assembly a little. I actually have play in line with the shift rod (up and down relative to the tranny tunnel) so I hope the new bushing eliminates that.


On my way into the garage this morning I ran my finger along the paint to see what Saturday's results were and I was not happy with the feeling. I also wasn't really getting any beading when I washed it - it was time. So I came back in, ate my words, and placed two more orders of products.


Detailers Domain:
-1 Gal Adam's All Purpose (may or may not have already depleted my small bottle :biggrin)
-Uber "FINE" Blue Clay Bar Kit


AutoGeek:
- Klasse AIO
- Klasse Glaze
- P21S Concours Look
- Microfiber and Foam Applicators
- Microfiber Buffing Towels


So.......THIS should do it. Or that's what I'll tell myself.


Plan will be to wash, clay, wash, AIO, buff, Glaze, wait 12 hours, buff, P21S, buff, P21S, buff. Should have it well protected for ~6 months and sexy-shiny for ~6 weeks.t of the common failure points addressed. Should be (knock on wood) smooth sailing after this for a while.

[BigDaveZJ]

Off topic, but did you fly in to Bradley by chance? Pam and I flew in there Thursday night as well.

New ride is looking damn good too!

[Jeeptech01]

Very nice work. I loke the attn to detail. Bummed about the paper filter though. Needs a CAI.

[ajmorell]

Very nice work. I loke the attn to detail. Bummed about the paper filter though. Needs a CAI.

I wouldn't be too quick to jump on the CAI band-wagon. I realize that a lot of engines do benefit from them but for some it's actually a step backwards...I can't comment on Paul's car specifically. Some of the newer intake designs are about as good as you're going to get from the factory.


Paul, that is one nice, clean Beamer. I have been looking for a 535 or 540 E39 with a manual but they are tough to find with decent mileage and in really good condition for reasonable prices.

[ATL ZJ]

How do you like the cupholders?

[paulkeith]

Dave, I flew into White Plains (HPN). This was on July 7.

Andy is dead on. The e46 intake (and exhaust) design is actually very, very hard to improve on. Especially with the ZHP's tweaked tune, bigger cams, and higher redline, this engine is very close to it's best performance without getting into forced induction.

In this picture:



You can kind of see, but the area behind the kidney grills is actually ducted up over the radiator support and into the stock airbox. This is actually the only air inlet to the stock airbox, so the only air going in is coming from the front grille. The only design proven to really tweak out a few more HP is the BMW Performance Intake, and it's $350 for 3hp at 6,000 RPM.

Andy, be careful with the E39 540s. They're great cars if maintained well, but can be an utter nightmare too. I've wanted a 2003 540i M Sport since like 2005.

Cam...



But, yeah, they're actually pretty good. Way better than a pretty similar design in my E36s. They hold a 20oz bottle or the large cup from Chick Fil A like a boss. They're very much in the way of the shifter, though, and you have to have the armrest up if you want to use both of them. Ze Germans aren't really big on the whole food in the car thing.

[ajmorell]

Andy, be careful with the E39 540s. They're great cars if maintained well, but can be an utter nightmare too. I've wanted a 2003 540i M Sport since like 2005.

Yeah I know. I don't exactly have the $$ in order right now anyways. There is just something about those E39s that grabs me, don't know what it is.

[ATL ZJ]

Haha, not serious... I'm diggin the car but since I have no clue what half the terminology in this thread is, I figured I would self-deprecate by asking the classic favorite question of people who are ignorant about cars. Glad you like them though.

[paulkeith]

- Upper & Lower Hoses
- Expansion Tank
- Air Filter x2
- Oil Filter x2
- Fuel Filter
- Activated Carbon Cabin Filter
- 14 QTs 5W30 BMW Synth
- 2 Gal BMW Antifreeze
- Hydraulic Tensioner
- Water/PS/Alt Belt
- Tensioner Pulley
- Idler Pulley
- A/C Belt
- Wiper Blade Refills
- Valve cover bolt trim caps
- New stud + washer + nut for 1 valve cover bolt that I found cross threaded

Here’s what that all looks like, plus the detailing products:



My crossthreaded and snapped valve cover stud:





All the new parts (washer, rubber retainer, bolt:





Stud in:



Done:



Simple stuff. Just cleaning up someone else’s durp.

Front all apart (air intake ducting off, fan out):



Scrubbed tensioner bracket plus new hydraulic tensioner:



Installed:



New tensioner pulley against old:



Belts on:



New tank in:





New cabin filter against old:




Figured you guys might find this interesting, BMW radiator hoses come clamped to plastic ends. The plastic ends are what mate to the radiator, thermostat, etc, and include a quick release metal clip. The expansion tank mounts the same way. Basically everything comes apart with no prying, yanking, etc. Makes working on this stuff very straightforward.











Paul

[ELLLLLIOTTTTT]

Gotta love German design. I can tell that this car is going to be in good hands.

[BigDaveZJ]

Figured you guys might find this interesting, BMW radiator hoses come clamped to plastic ends. The plastic ends are what mate to the radiator, thermostat, etc, and include a quick release metal clip. The expansion tank mounts the same way. Basically everything comes apart with no prying, yanking, etc. Makes working on this stuff very straightforward.

I wonder if you could mount one of those connectors on PVC?

[Jeeptech01]

Hmm interesting about the cai. I suppose Im more used to lower end vehicles that have the heimholtz? valve integrated into them that dampens intake sound and robs power. Cool rig man.

[ajmorell]

It's called a helmholtz resonator dipshit ... duh

[paulkeith]

I wonder if you could mount one of those connectors on PVC?

dammit dave!

[Jeeptech01]

It's called a helmholtz resonator dipshit ... duh

I pulled it from memory not google asswipe

[suruba]

great job taking care of it, looks like you've got yourself a great ride there, love the ZHP

Dave

[paulkeith]

Gotta love German design. I can tell that this car is going to be in good hands.

In hindsight, this right here turned out to be a pretty funny statement. In good hands/under minivans. Either or.

It's newer, younger, darker brother....an '05 with 92k, otherwise pretty much the same:

[paulkeith]

How I picked it up (body color molding, clear corners, very dirty):

[paulkeith]

Logged about 5,000 miles so far. No major complaints.

mods so far:

alcantara tri-color stitch wheel conversion:

old:


new:






new headlight lenses:





short shift kit and double shear selector rod:









maintenance-wise largely the same treatment the last one got. expansion tank, water pump, hoses, coolant, oil, etc. waiting to do plugs and control arm bushings.