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Zedonist Z3 1.9 M44B19

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  1. zedonist

    zedonist Guest

  2. zedonist

    zedonist Guest

    Started to prepare all the bits for the big brake upgrade, 3.0 on a 1.9, stripped, cleaned and painted the calipers, discs and disc shields arrived, gave the shields a coat of black satin plus lacquer, just waiting on the pads now and ready to go:
    IMG_0011.jpg
     
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  3. badman gee

    badman gee Guest

    Looking good sir
     
  4. Brian H

    Brian H Zorg Guru (V)
    British Zeds Scottish Zeds

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    The parts have cleaned up really well, Which pads are you using? I have a new set of EBC red stuff pads for sale.
     
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  5. badman gee

    badman gee Guest

    Red stuff are excellent, very low dust and good stopping power
     
  6. zedonist

    zedonist Guest

    I have ordered some Red Stuff pads for the front, should be here Monday, can't believe I missed yours Brian, do you have rears available too?
     
  7. Brian H

    Brian H Zorg Guru (V)
    British Zeds Scottish Zeds

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    That's a real shame unfortunately only have the fronts.
     
  8. badman gee

    badman gee Guest

    Y fronts?
     
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  9. zedonist

    zedonist Guest

    Z3 M44B19 Front Brake Upgrade and Front Wheel Bearing Change


    Time – 2 hours per side

    Cost – With Upgrading Brakes - £275 – extra for new parts

    Bearings only - £75


    ***Important Read Before You Start***


    1) The Brake Disc Retaining Screw is a hex drive and has a tendency to corrode in place, resulting in a stripped drive, so a good HSS Drill Bit and stud extractor kit in the wings may prove handy.

    2) The Front & Rear Dust Covers are not included in the wheel bearing kit, and there is a good chance you will damage when removing.

    3) All the above items are dealer supply only, and at most dealers order on request only, so ensure you buy these parts and have them ready before you start, as you will not be able to complete the job without them.



    4) Full tool and parts list at the end of the document. 46mm Sockets are not readily available over the counter, three leg puller is a must, so order these off the internet, or if you are local I can lend these items out.

    5) A list of compatible donor cars should you wish to use salvage parts is at the end of this document.


    The process (both Brake upgrade and wheel bearing change)


    1) Jack the car up, remove the road wheel and secure the car on an axle stand.

    2) Attach a tube clamp to the brake line to the calliper, and loosen the brake line (14mm Spanner) do not remove at this stage. You do not need to do this step if you are just doing the wheel bearings.

    3) Undo the two 16mm bolts (Breaker Bar and 16mm Socket) that hold the brake carrier to the hub, remove the brake calliper from the disc. If you are doing wheel bearings only, suspend the calliper from the front spring using the bungee cord. If you are upgrading the brakes then now you can undo the brake line completely by twisting the calliper.

    IMG_0608.JPG

    4) Using the correct hex socket remove the disc retaining bolt. If you have a corroded bolt then now is the time to use the HSS Drill Bit and Stud Extractor Kit.

    5) Remove the Disc from the Hub.

    6) Prise out the front dust cover from the hub using a thin bladed screwdriver or similar, if you are lucky you can re-use. If not then hopefully you already have the new one available.

    7) You should now have access to the hub nut. The hub nut is staked to the hub, so take a large flat bladed screwdriver or similar and remove the stake.

    IMG_0552.JPG

    8) You can now undo the hub nut using the 46mm socket and a breaker bar, you may need to utilise an extension bar on the breaker bar to get extra leverage.

    9) Now that the hub nut is removed you can use the three-leg puller to remove the hub, in some cases the hub will be loose and just pull off, in either case it will leave the inner race in place.

    10)With the hub removed you can now remove the brake shield with a 10mm spanner and remove the three retaining screws.

    11)With the brake shield removed you should be able to get the three-leg puller behind the rear dust cover, or if you are lucky behind the inner race only, and remove the inner race. If you have damaged the rear dust cover then you should have a new one available if you heeded my advice at the beginning.

    12)Now the rebuilding

    13)Place the new rear dust cover in place, it will not go on all the way, but don’t worry, as the tightening of the bearing will push it firmly home.

    14)Replace or put back on the brake shield 3 bolts, take time to clean your wheel sensor with brake cleaner first.

    15)The new bearing should already be packed with grease, if not pack the bearing with grease and push on to the hub as far as it will go. Gently tap the bearing on with the 46mm socket and a soft mallet until you have the threads exposed. You can now wind the bearing on using the new nut from the kit, tighten up to 290Nm.

    16)Stake the nut to the hub.

    IMG_0603.JPG

    17)Replace the front dust cover

    18)Now give your brake disc a good clean with brake cleaner to remove any grease and mount to the hub, lineup the holes correctly and centre with two wheel bolts, apply some copper grease to the retaining screw and fix the disc to the hub, only nip the retaining screw up as it will make it easier to remove next time.

    IMG_0606.JPG

    19)Attach the brake calliper (if replacing) to the brake line and tighten up with a 14mm spanner.

    20)Push the brake calliper onto the disc and align the holes of the carrier with the hub, replace the bolts and tighten with a 16mm socket to 110Nm.

    IMG_0610.JPG

    21)If required bleed the brakes.

    22)Jack the car up and remove the axle stand, replace the road wheel, and lower the car to the ground.

    23)Tighten the road wheel bolts to 112Nm (recheck after 100miles).


    Job Complete


    Tools


    · Wheel Brace (or 17mm Deep Socket)

    · Breaker Bar

    · Torque wrench up to 400Nm

    · Large flat blade instrument (screw driver, chisel)

    · Thin bladed instrument (screw driver, knife blade)

    · 16mm Spanner

    · 16mm Socket

    · Ratchet

    · Set of Hex Keys or Sockets

    · Stud Extractor

    · 10mm HSS Drill Bit

    · Drill

    · 46mm Socket

    · 3 Leg Puller

    · 10mm Spanner

    · 8mm Spanner

    · Brake Bleed Kit

    · Hose Clamps

    · Bungee Cord

    · Trolley jack

    · Axle Stand


    Parts


    · Wheel Bearing Kit (includes Nut) – Part Number - 31226757024

    · Front Dust Cover – Part Number - 31206777789

    · Rear Dust Cover – Part Number - 31206777788

    · Brake Disc Retaining Screw – Part Number - 34211161806

    · Brake Shield – Part Number – 34111158985 Left and 34111158986 Right

    · 3.0 Vented Discs* – Part Number - 34116864058

    · 3.0 Brake Callipers* – Part Number – 34116758113 Left and 34116758114 Right

    · 3.0 Brake Carriers* – Part Number - 34106758120

    · Brake Pads of your choice – Red Stuff was my choice

    · Brake Cleaner

    · Brake Fluid

    · Bearing Grease

    IMG_0410.JPG

    IMG_0551.JPG

    * Compatible Donor BMW vehicles for salvage items

    E46: Details on E46
    E46 323Ci Convertible
    E46 323i Touring
    E46 325Ci Coupe
    E46 325Ci Convertible
    E46 325i Touring
    E46 325i Sedan
    E46 325xi Sedan
    E46 325xi Touring
    E46 328Ci Coupe
    E46 328i Sedan

    E85: Details on E85
    E85 Z4 3.0i Roadster

    Z3: Details on Z3
    Z3 Z3 3.0i Coupe
    Z3 Z3 3.0i Roadster
     
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  10. zedonist

    zedonist Guest

    These just arrived:
    IMG_0647.jpg
    Refurbed (Ultrasonic cleaned & and all new consumable parts) matched set for flow and volume
     
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  11. zedonist

    zedonist Guest

    Z3 M44B19 Fuel Injector Replacement

    Time – 3 hours

    Cost – Full set of Fuel Injectors, reconditioned, ultrasonically cleaned and matched flow rate £58

    Source - Bavarian Werke Fuel Injector Store – E-Bay

    Difficulty Rating - Dark Spanner.png Dark Spanner.png Light Spanner.png Light Spanner.png Light Spanner.png

    Tools


    Spanners 10mm, 11mm, 13mm
    Flat Bladed Screw Driver

    ***Important Read Before You Start***

    1. You are completing a job that requires venting of the fuel system, please ensure that you take the necessary precautions:

    a. Work in a well ventilated area
    b. Be prepared to catch and control any spills
    c. Have a fire extinguisher available at point of use

    2. I am not responsible for your safety, so please assess the risks of doing this job yourself before starting, and get a mechanic to complete for you if you do not feel safe.

    The Strip Down

    Open the bonnet (hood for our American friends)

    SAM_2088.jpg

    Unplug the MAF and remove the Air Temp Sensor

    SAM_2095.jpg SAM_2097.jpg Dark Spanner.png Light Spanner.png

    Undo the throttle body gaiter band clip and remove the vacuum hose

    SAM_2098.jpg SAM_2099.jpg

    Unclip both throttle body sensor plugs

    SAM_2101.jpg

    Remove both vacuum hoses from the throttle body

    SAM_2102.jpg SAM_2103.jpg


    See Part Two
     
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  12. zedonist

    zedonist Guest

    Z3 M44B19 Fuel Injector Replacement - Part Two

    Undo the band clip on the top vacuum hose on the plenum chamber and remove the hose

    SAM_2115.jpg

    Undo the plenum chamber centre bolt and two side nuts

    SAM_2111.jpg

    Undo the front and back plenum-retaining bracket bolts do not remove fully

    SAM_2113.jpg SAM_2114.jpg

    Remove the top plenum chamber and place to on side


    SAM_2116.jpg

    Remove the rocker cover breather pipe

    SAM_2118.jpg


    Remove the fuel rail bleed nipple cap

    SAM_2121.jpg

    Now you have access to remove the pressure from the fuel rail, ensure that you put some rags or cloth around the area as you will release fuel when doing this next step.

    Using a suitable tool (star screw driver) depress the bleed nipple (similar to loosing air out of your tyre) until no more fuel runs out.

    Ensure you mop / dry up any fuel.


    Undo both fuel supply lines and then unscrew the fuel rail, be careful the fuel rail contains fuel, but it is not under pressure, if you followed the previous step, ensure you capture any spillage.

    SAM_2124.jpg
    SAM_2123.jpg

    See Part Three
     
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  13. Brian H

    Brian H Zorg Guru (V)
    British Zeds Scottish Zeds

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    Nice touch with the spanner symbols.
     
  14. zedonist

    zedonist Guest

    Z3 M44B19 Fuel Injector Replacement - Part Three

    The fuel rail together with the Injectors should now pull free, disconnect the electrical connectors (careful not to lose the spring clips)

    SAM_2125.jpg

    You can see how dirty the Injectors are and how the o’rings have shrunk over time to allow dirt and oil in and around the Injector


    SAM_2128.jpg
    SAM_2135.jpg

    With the fuel rail assembly on the bench you can now unclip the injectors by removing the metal clip with a flat blade screwdriver and pull the injectors free and remove the vacuum hoses

    SAM_2141.jpg SAM_2142.jpg SAM_2143.jpg

    Fitting the new injectors is a reversal of the removal, push the injector home and slide in the clip, attach the vacuum hoses


    SAM_2145.jpg SAM_2150.jpg

    When refitting the fuel rail system back into the engine, line the injectors up with the relevant port, and attach both fuel lines first, and then the two fuel rail bolts, the tightening of the bolts will pull the injectors home into their ports (no excessive force required)

    SAM_2151.jpg

    Rebuild is a reversal of the strip down procedure – Job done!

    SAM_2153.jpg


    Well initial reports are that it was a job worth doing, the engine sounds smoother, and pulls a lot stronger, and the legendary M44 rough idle is no longer present, mind i can understand with the state the Injectors and seals were in.
     
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  15. zedonist

    zedonist Guest

    Oil & filter change completed tonight, also took the time to mark out the fixing holes for the front spoiler, just got to paint it up and fix in place.

    Following that just got to MOT and Tax ready for some spring fun
     
  16. z3cade

    z3cade Zorg Guru (III)
    East Anglian Crew

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    Looking good ;) all the hard work will pay off when that sun comes out!
     
  17. zedonist

    zedonist Guest

    Thanks Liam, rear subframe bushes to do backend of the year, and then it is just body work (Respray)
     
  18. z3cade

    z3cade Zorg Guru (III)
    East Anglian Crew

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    Not thought about a wrap? Can work out cheaper than paint and almost any finish available
     
  19. zedonist

    zedonist Guest

    Induction Pictures for Joey:

    SAM_2170.JPG SAM_2169.JPG SAM_2168.JPG SAM_2167.JPG SAM_2166.JPG SAM_2164.JPG SAM_2163.JPG SAM_2162.JPG SAM_2161.JPG
     
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  20. zedonist

    zedonist Guest

    Painted the Rieger Front Spoiler this weekend, just got to polish and then fit:

    SAM_2154.JPG
     

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