"Solaire" - 2001 M54 2.5i Roadster

estgray

Dedicated Member
American Zeds
Joined
Aug 12, 2023
Points
28
Location
Washington State, USA
Model of Z
2.5i
This is my first fun car, and the first that I actually purchased with the intent to do work on myself and turn it into a project---my wife and I try to do most of the work on her Volvo, but it's hers and so not a canvas for my modifications. I figure a progress thread will at least help me keep track of the journey.

The Beginning

The car is a titanium silver metallic roadster from 2001. It's a 2.5i and I'm in the USA so it is left hand drive. If I recall correctly there are three previous owners, the most recent of which is a friend of mine from work. He happened to be selling just as I got the bug to have a stickshift car around, my wife was on board with the idea, so we pulled the trigger.

As it came it had about 79960 miles on. It had been a California car for most or all of its life, so though I haven't been under it yet I'm not expecting much rust. Accessory belt was just replaced, along with a new set of rear tires. The rear window is also a fairly new . My friend had owned for about 4 years and did most of the maintenance himself. He's a car guy and the mechanicals were well looked after.

IMG_20230520_154836363_HDR~2.jpg

The car came with a half cover and the original BMW full cover, some random containers of extra fluid like some ATF for the power steering, a fan clutch wrench, and some manuals. My friend says he had the service receipts from the first owner somewhere, but couldn't find them, so I've only got a few from the second and third.

It also came to me with a few modifications: an M sport shift knob, plus some new bushings and other shifter mods that I still need to get the parts list for if he can find it (it's a very solid, notchy throw); a stud conversion with 75mm studs, a sticker on the right front quarter panel that has given the car its name, and some Hello Kitty valve stem covers that I thought I'd replace right away but I had largely forgotten about.

IMG_20230817_182851610.jpg

When I get the chance to add the next update, I'll detail what I've done so far.
 

Shoejohn

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Joined
Aug 4, 2023
Points
28
Welcome to the forum! Great looking console! More refined than the pre facelift. Here is a look at mine. It’s nice to see them side by side.
IMG_4700.jpeg
 

Shoejohn

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Aug 4, 2023
Points
28
Correct. Our pre facelift consoles look identical. I have the Leather Z armrest too. Love that upgrade.
 

Mus Musculus

Zorg Guru (II)
Supporter
British Zeds
The M44 Massive
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Nov 27, 2022
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Ramsey, Huntingdonshire
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1.9 M44
Hi and :welcome: to the forum from Cambridgeshire, UK.
 

estgray

Dedicated Member
American Zeds
Joined
Aug 12, 2023
Points
28
Location
Washington State, USA
Model of Z
2.5i
Correct. Our pre facelift consoles look identical. I have the Leather Z armrest too. Love that upgrade.
I hadn't seen the pre-facelift before, thanks for sharing. I like the add of the chrome trim rings and the clock, though clearly mine is missing some options as there are a couple blanking plates on that bottom row.

IMG_20230819_112731648.jpg

Edit: had a moment to take a photo. Mine has the "BMW Business CD" player. Probably the biggest thing that bugs me aesthetically is that it's just a big black rectangle and not integrated. But that makes it easy to swap I guess.
 
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estgray

Dedicated Member
American Zeds
Joined
Aug 12, 2023
Points
28
Location
Washington State, USA
Model of Z
2.5i
Taking Stock

Our first task with the Z3 was to drive it up from California to Washington, a total trip of around 900 miles, stopping to see family for a night in the middle. From this trip I learned:
  • The car is in decent shape, everything electrical seems to work including foglights, cruise control, top motor. It's surprisingly comfortable for long distances actually, I wouldn't say it is a great roadtrip car but I expected worse.
  • It's loud at 70mph. Nothing to be done about that, but I was glad we brought ear plugs after a few hours
  • The stereo is dreadful. I think the woofer may need refoaming or something else is wrong. Low priority item, since I don't think I'd use the stereo frequently in this car.
  • It tramlines quite badly, and likes to follow dips in the road. Mostly it was manageable but there was a section of freeway in southern Washington where it really fought my attempts to lane change, and then went very abruptly as I got the tires out of the grooves worn into the surface. I can accept some of this behaviour but I need to reduce the issue.
  • The driver's seat slides forward and backward slightly. The passenger's seat is more stable. This is only really annoying in stop and go traffic, not when cruising.
  • The gear shift works fine but isn't consistent. As it heats up the shifts get notchier. Not worried at the moment but I did notice changes in how hard it was to get into gear.
  • There is a clunk from the driveline on throttle on/off applications. There's also a sharp clunk or rattling sound that sounds like the right rear strut over sharp impacts (not a speed hump, but small bumps, expansion joints or just road texture).
  • Fuel economy on our mostly highway trip was in the realm of 28 mpg (best 30, worst 26). Torque feels good, so not currently concerned about Vanos though I've no record of seal replacement.
Based on this I made a list of todo items, roughly in order of importance:
  1. No record of cooling system refurb, so I plan to replace the water pump, rad, and all hoses. Currently stuck deciding on an aftermarket radiator and waiting for winter before I take the car off the road
  2. Address the tramlining, starting with a replacement of all suspension bushings
  3. Increase chassis stiffness wherever possible (strut brace, "butt brace" if I can get one. Already reached out to Strong Strut on this)
  4. Replace the seat bushings, especially driver's side
  5. Look into clunking sounds (maybe a driveshaft issue, but planning to replace diff bushing first and check again). My friend (the previous owner) says he checked for the other clunk multiple times and it isn't the strut, it's something rattling inside a bumper he thinks.
  6. Fix the stereo
  7. Paint correction and dent repair
  8. Other aesthetic changes I've been thinking about, like wheels etc.
Whew! That ought to keep me busy for a bit.
 

estgray

Dedicated Member
American Zeds
Joined
Aug 12, 2023
Points
28
Location
Washington State, USA
Model of Z
2.5i
First Things First

So of course, when there were lots of mechanically important things I could be doing, I started at the bottom of the list with aesthetic upgrades.

My first wrenching task was to space out the wheels a bit. I wasn't looking to have to roll the fenders, but the fronts sat at an acceptable 5/16s inside the fender (measured from the outside top of the fender to the outside top of the tire, at its widest point just below the tread blocks): enough overhang to catch debris from the road but still looking pretty flush. The rear was a different story, with an ovehang of 19/16ths on the left rear and 22/16ths on the right. The difference from the front was partly due to the significant negative camber bringing the top of the tire inward. (And when I researched, this asymmetry between right and left sides at the rear seems common.)

So I ordered some 20mm spacers from Turner and bolted those up, with some longer 96mm studs. The car had already been converted to studs with 75mm ones all round. Also gave me a chance to check out the rear brakes and springs/struts which all look fine.
IMG_20230722_160640_01.jpg

IMG_20230722_161544_01.jpg

After installation, much better looking, though the suspension hasn't settled in this photo: IMG_20230722_165136_01.jpg

Happy with the change so far! Now 3 corners look pretty much identical. The right rear is still less than ideal but you don't notice unless you look very closely, and given it seems to be asymmetric by design I'm likely to just leave it.
 

estgray

Dedicated Member
American Zeds
Joined
Aug 12, 2023
Points
28
Location
Washington State, USA
Model of Z
2.5i
A Bit of Cleaning

Just chipping away at little things while the good summer weather is here. I don't want to take the car out of commission while it's nice to drive, so the last few work items have just involved giving the car a good clean inside and out. First, got rid of a bunch of the dust and gunk from the engine bay.

Before: IMG_20230817_174131981.jpg

And after: IMG_20230817_182730203.jpg

It's not perfect but it is progress. Cleaned inside the air intake box too and found some old leaves and stuff hanging out there. Also went around getting all the spots you tend to miss: front wings under the edges of the hood, behind and under the doors, etc. Didn't get to the trunk yet so that's my next stop.

Also cleaned up the wheels which were dusty. There are a few spots that didn't come clean with wheel cleaner and scrubbing, some may be scratches into the paint. This is the best looking of the lot:

IMG_20230801_194541_01.jpg

Finally, got as much clean as I could of the interior without removing the seats. Vacuumed the mats and behind the seats. I found some items from the last 3 owners under the seats, including a ticket stub to Superman from 2006 (owner #1) and a Bollywood CD (owner #2 I'm guessing).

IMG_20230822_144443_01.jpg

Just received a touch up pen and some billet aluminium pedals from Turner this week so some chips on the front splitter and installing the pedals will probably be the next updates.
 

estgray

Dedicated Member
American Zeds
Joined
Aug 12, 2023
Points
28
Location
Washington State, USA
Model of Z
2.5i
New Pedals

These showed up last week from Turner: IMG_20230902_135626076.jpg

This was mostly an aesthetic purchase. I thought that the car could use a bit of bling on the interior, and the black rubber pedals just weren't doing it for me in the looks department. Besides, the tread on them was a bit tired.

Followed the instructions in the package: pull off the old rubber covers, wrap with painter's tape, mark the holes, and drill first at 1/8". Jumping to 3/8" seemed a bit far, and larger than necessary based on the sizes of the included bolts, so I went to 5/16" on the clutch and brake. The brake is a tough one as it's metal, fairly thick, and everything is done at an awkward angle in the footwell.

IMG_20230903_160548700.jpg

Then you pull the tape and bolt the pedals in using locking nuts on the clutch and brake, and self tapping screws on the plastic throttle pedal. I got worried about the top left screw impinging on the pivot mechanism so I dropped down to one of the lower holes. I think it's a rather good look actually.

IMG_20230903_164404758.jpg

I've gotten an hour or two of driving in on these so far and my biggest surprise is there's a performance benefit. The throttle is a bit bigger and 1/4" closer due to the extra layer of aluminium, nicer for throttle blip downshifts. And the other pedals have so much bite that your foot isn't going anywhere, which I find helps precisely control the clutch.

All in all it's a nice little mod and only took me an hour or so start to finish. The only thing lost is the little deflector moulded into the brake pedal cover to keep your foot from getting stuck behind by accident, but after deliberately trying to get my foot stuck with these unprotected pedals it really doesn't seem that necessary.
 

estgray

Dedicated Member
American Zeds
Joined
Aug 12, 2023
Points
28
Location
Washington State, USA
Model of Z
2.5i
Not much progress has happened on the car in the last month---lots of other projects instead, notably a railing for our front porch.
IMG_20230922_185327695.jpg

So just a few little things to report. Car got a full clay bar and some touch up paint. Covered up some nasty scrapes from someone's parking lot mishap (see the rear bumper below), and some little stone chips on the bonnet. There's more to do but touch up never looks quite the same so I focused on the most pressing issues rather than risking making tiny chips worse.
IMG_20230910_094455687.jpg

Then a full polish and wax with Meguiars mirror glaze. The paint is nice and smooth now.
IMG_20230904_180237990.jpg

I've taken a couple hour plus drives and stretched it's legs with some highway miles at speed. Still chuffed with the Turner pedals, a great choice.

As it gets colder here, the only intermittent issue is with the heat, which doesn't seem to work unless the fan is turned up to 4 and then back down. Any ideas on why?
 

t-tony

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British Zeds
#ZedShed
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Dec 31, 2013
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Torksey Lock,Lincoln, England
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E89 Z4 23i Auto
It sounds as thought the speed rheostat is maybe getting tired. When they fail completely the fan will only run on full speed so perhaps it is on it's way out?

Tony.
 

estgray

Dedicated Member
American Zeds
Joined
Aug 12, 2023
Points
28
Location
Washington State, USA
Model of Z
2.5i
It sounds as thought the speed rheostat is maybe getting tired. When they fail completely the fan will only run on full speed so perhaps it is on it's way out?

Tony.
Interesting theory. The fan does work though, it'll hold any speed and doesn't need to be maxed to start. It just continues to blow cold air, even with the heat turned to max, until the fan is turned to 4. Then it'll be hot at any speed you pick, until you turn the heat knob down and the process repeats if you want heat again.

Not sure if that behaviour still fits your theory. I'm making do for now but if it gets worse I'll be looking for a fix for sure.
 
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