AlexGSi2000's Z3

AlexGSi2000

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Mar 31, 2025
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28
Location
Liverpool, UK
Model of Z
3
Thought I would start a progress thread for my recently acquired 2002 Z3.

Z3's were never on my radar in years past, however, having recently purchased a newer 5 series, it gave me a serious desire for something small, analogue and old school, without breaking the bank.

The 5 series is great, its smooth, powerful - the 8 speed ZF box is fantastic, however on the whole, it feels numb and a step further away from "driving", its essentially a point-and-shoot car, it will get there quickly and tackle most roads well, however you never feel too "involved".

My criteria for purchasing the Z3 was to have something for occasional use and also to have as a light project.
The Z3 will have the sole purpose for going out and enjoying the roads during the summer months.
Therefore, the work I carry out on the car will be carried out with handling improvements in mind.
The car will live in my garage for most of the time, its now time for this car to get the love it deserves / semi-retirement after a busy life so far.

I collected my Z3 in early April of 25' for the sum of £2,150 - its fairly high miles at 150k, however it doesn't bother me too much as suspension components.etc will be replaced over time.
Originally I was looking at the 3.0, however with a budget in mind, it was more appropriate to select the 2.2.
With the M54 engine in mind, my thoughts are that its going to be easier to swap in a 3.0 when the time comes.

Its clear that the car has been loved at some-point, but in recent years has probably not quite had the attention it deserves, there are lots of little niggles that need addressing, my plan is to address these first and then move onto improvements.

After getting the car home, my first plan was to formulate my initial list;
- Bonnet release catches / Bowden cable. One of the catches was missing and the other released by pulling the cable from under the bumper.
- Instrument cluster - Dials not illuminating, sometimes shows ERR_2 along with the dials not working
- Paintwork - Probably one of the flattest cars Ive seen when it came to paint, loads of oxidation to the point I thought it was unrecoverable.
- Handling - The car feels a little woolly / unsure / vague.

After reviewing the previous invoices / receipts, I was pleasantly surprised to find an invoice from 2020 showing the car had somewhat of a rear end refresh - the rear trailing arms had been replaced, along with the fitment of a few polybushes and diff mounts.

I had the car on the ramp over the weekend - it was going to be a make or break moment for the car, if it was rotten then the project may end up being a failure to launch.
I was pleased to see that the corrosion was as expected for a car of this age and mileage - nothing too serious and far from being rotten. The sills / front arch panels will need addressing at some point, but they are still solid in the key areas / jacking points.etc

The shocks are original to the car and will be well past their best, one of the coils on the front springs has cracked / failed - so I think this may well help explain the iffy / unsettling handling.
I have ordered a set of MTS coilovers in order to address / stiffen the ride a little.

I spent a good few hours taking advantage of the fantastic weather we had this weekend and treated the car to a full machine polish and wax, to my surprise, most of the heavy oxidation was lifted, a few before and after shots;

Heavy Oxidation on the bonnet;
Paint1.jpg


After a quick test patch with a cutting pad & Menzerna cut force pro;

Paint2.jpg


50/50;

Paint3.jpg


Final result, I wet-sanded and polished the headlights also;

Paint4.jpg


Paint5.jpg


I tried on a set of Style 66 I had laying around from one of my old e39's - I love the rear fit, however the fronts are a tad too wide.
Will be on the lookout for a different set of wheels over the next few months, quite fancy a set of wheels with a nice dish.

Style66.jpg


Thats all for now - will report back in a few weeks.
 

John_B

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Z3's were never on my radar in years past, however, having recently purchased a newer 5 series, it gave me a serious desire for something small, analogue and old school, without breaking the bank.

The 5 series is great, its smooth, powerful - the 8 speed ZF box is fantastic, however on the whole, it feels numb and a step further away from "driving", its essentially a point-and-shoot car, it will get there quickly and tackle most roads well, however you never feel too "involved".

My criteria for purchasing the Z3 was to have something for occasional use and also to have as a light project.
SNAP! =))
and then...

My Z3 journey started two years ago for the exact same reasons as you described. I started with a high mileage 1.9, but last summer upgraded to a high-but-not-as-high mileage 2.8 last year (also in black). In hindsight I wish I had started straight off with the 2.8, but I was being impulsive and also learned some key points of what to do (and what not to do) with the 1.9 beforehand.

Welcome, and I'm looking forward to following your progress :)
 

Z Victor 1

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E 89 Z4 S drive 23i
That looks just like my old 2.2i sport, sapphire metallic black with red and black interior. :thumbsup:
 

AlexGSi2000

Dedicated Member
Joined
Mar 31, 2025
Points
28
Location
Liverpool, UK
Model of Z
3
Friday night after work saw the installation of a set of MTS coilovers, along with a set of rear upper and lower braces and some wheel spacers.

My word, what a difference its made - its completely changed the characteristics of the car.
The original suspension from 2002 and 155k miles was certainly due replacement.

The ride is much more firm, which is exactly what I was after, the car feels more focused.

The car will only be used occasionally, the budget didnt quite allow for all singing all dancing coilovers, at the same time I didnt want to go for cheap and nasty ones (been there, done that), these seem a good middle of the road option, only height adjustable, the springs are also supplied by Eibach.

Its sparked another level of excitement to be fair, I enjoyed driving the thing already, this seems to be quickly becoming my favorite "fun" car.
 

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Scooblitz

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They are charming little cars these z3s. You will fall in love quickly.

2.2i is a good choice and this one looks to have a nice spec as well. A ‘sport’ front what I can see. Looks lovely after its polish.

The E39 wheels are perfect on the rear but the fronts will be 15mm too much poke from the arch. For the fronts, 8 inch width with Et35 offset is the outer limits for flush arch fitment. I run 17x8.5 et41 on front (rear z3 wheels) which is same equivalent poke. Any more is going to need skinny tyres, shims or camber plates.

Having the trailing arms and subframe bushes done is a massive plus. It’s quite an involved job to replace.

What other plans have you go for it?

Stevie
 

AlexGSi2000

Dedicated Member
Joined
Mar 31, 2025
Points
28
Location
Liverpool, UK
Model of Z
3
Hi Stevie,

Short term plans are to replace the wheels for something a little more me - Been looking at a set of BBS Replicas (Dare DR RS), with some half decent rubber.
Following on from that I mainly plan to enjoy the car over the summer months.
Dont get me wrong, the car is full of little niggles here and there, seat runner slack, missing button blanks.etc all of which I'll attack as and when.

Medium term plans (Winter 25 into 26) will be to pull the 2.2 and leave a 3.0 in its place.
The 2.2 feels like it just needs a little more - especially coming out of corners, I feel the power from a 3.0 should be just right.

Longer term - who knows.
After the engine, I should really turn my attention to my e39 that's been sat under a cover for the past 12 months.
 

AlexGSi2000

Dedicated Member
Joined
Mar 31, 2025
Points
28
Location
Liverpool, UK
Model of Z
3
Wheels were replaced this evening.

I went for a set of BBS RS replicas in 18" Dare DR RS.

I half feared 18" would look too big, but I think with the lower profile tyres and the lowering - it just about pulls it off.

Went for Kumho PS72 tyres - I believe they have only recently been released and have good reviews so far.

Will get some better photos over the weekend.

z31.jpg


z32.jpg
 

AlexGSi2000

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Joined
Mar 31, 2025
Points
28
Location
Liverpool, UK
Model of Z
3
Took some better photos over the weekend;

IMG_2087.jpg


IMG_2086.jpg


IMG_2089.jpg


I also sold the original style 78 wheels, which in turn freed up some funds for the following;

Screenshot 2025-05-14 113225.jpg


I had an ebay saved search running for an M54B30 - one turned up earlier today, from a breaker I have used many times previously, a quick whatsapp message secured the deal at a very reasonable price compared to others listed on ebay.

I was anticipating holding off for a little while longer, but this one appeared at the right price, so couldnt let it get away.

Plan is to do a quick refresh on the engine when it arrives - new gaskets / seals, clean out & inspect the VANOS and fit an oil pump chain tensioner.
At the same time I'll accumulate other bits and bobs needed - I'm sure I need a center bearing too.

The plan is to see how she goes using the current 5 speed drivetrain / diff.etc - I'm not going to be looking for more than standard power on the M54B30 at the moment, so I'm "hoping" its all man enough to deal with it.
 

1955Davidr

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Great looking wheels but I am biased, latest addition to our fleet next to the Z.

IMG_4402.jpeg
 

AlexGSi2000

Dedicated Member
Joined
Mar 31, 2025
Points
28
Location
Liverpool, UK
Model of Z
3
The engine turned up last Friday, was like Christmas day.

I've been helping a friend do his timing chain on an N47 engine over the past few evenings, so didn't have the chance to get started until yesterday.

Engine is ready to go onto the stand so I can replace a few of the gaskets in preperation.
Should have the following bits with me in the next few days;

Rocker cover gaskets, Oil filter housing gasket, waterpump and thermostat gaskets, rear main seal, sump gasket, inlet manifold gaskets, 3.0 intake boots/elbows, plugs, oils, fluids, 3.0 airbox, lots and lots of brake cleaner.

Its my first time doing any work on an M54, thankfully a few close friends have abit of experience with them, I've been advised to replaced the DISA as its not holding itself open, as well as removing the PCV drain back to the sump, as they get blocked supposedly.
As well as adding a tensioner for the oil pump chain.

The plan is to get all the gaskets fitted whilst the engine is on the stand, whip the 2.2 out the car and swap over any bits I need such as the sump, then drop in the 3.0.

Digital Tuning, who are not too far from me are going to flash the ECU whilst I'm swapping the engines so its ready for the 3.0.

Im sure I may need a few other bits along the way but I think I'm as prepared as I can be, within reason!

I also picked up a good set of 330i brakes to fit at the same time - figured it would be wise to beef up the brakes slightly.

Eng101.jpg
 

AlexGSi2000

Dedicated Member
Joined
Mar 31, 2025
Points
28
Location
Liverpool, UK
Model of Z
3
Its almost time to start swapping the engine over.

Progress has been a little slow as I've been obtaining parts for the engine refresh - spread across two paydays and when I've found discounts.etc

As it turns out, I've now spent more on engine parts than the actual engine itself :D - I could have just chucked the engine in as it was, but as I'm planning on keeping the car for a while, I thought it would be worth giving it a mini birthday.
I've never heard of timing chain guides.etc going bad on the M54, however as they are all getting on abit (this one being 23 years old) I thought it best to renew the chains and tensioners.

UKDT_IP1.jpg


As the car will be seeing a few spirited runs and potentially a trackday in the future, I wanted to try and mitigate the common oil sprocket nut issue, by way of adding a tensioner to the oil pump chain.
This was done by drilling a 6mm & 3mm hole, tapping the 6mm to m7x1.0 and fitting the tensioner (VAG part), the tensioner was less than £10.
Seems to keep the chain nice and tight - a little thread lock on the nut for good measure.

IMG_2454.jpg


IMG_2450.jpg


Engine now timed back up;

IMG_2464.jpg


I did consider rebuilding the vanos, but at this moment in time, I'm not wanting to spend any more than I need to - I can always revisit the vanos as its easily removed whilst the engine is in situ.
I have a small emergency fund to replace anything whilst the engines are being swapped - never know if a pipe.etc may be past its best.
Typically the two coolant pipes that run under the intake manifold were as brittle as sugar glass and fell apart as soon as I looked at them, so have those on order.

At this point, there isn't a great deal more to be done whilst the engine is on the stand, timing cover is back on, need to do the crank seals both ends, then I'm at a point whereby I'll need to start taking the 2.2 out, as there are a list of things that will need swapping over to the 3.0;
Sump, engine mounts.etc
Im going to be using all ancillaries from the 2.2 as I know they are good, some of the parts I removed from the 3.0 seem to be cheap reproduction parts such as the starter & alternator.

Hopefully the next lot of photos will show both engines side by side!
 

AlexGSi2000

Dedicated Member
Joined
Mar 31, 2025
Points
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Location
Liverpool, UK
Model of Z
3
Well, here we go...

Moved the Z3 to the unit yesterday evening, quickly pulled the bonnet off as I had a spare pair of hands.
Pulled the ECU as I'm taking it to Digital Tuning Solutions on Friday to have it flashed ready for the 3.0.

Will start pulling the engine after work tomorrow, cant believe how much I'm looking forward to the power increase.

Made sure the 2.2 had a good send off on the way to the unit anyway!
Hadn't driven the car in two weeks and was instantly reminded of how much I bloody love this thing.

IMG_2507.jpg
 

AlexGSi2000

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Joined
Mar 31, 2025
Points
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Location
Liverpool, UK
Model of Z
3
Finished removing the 2.2 this evening. Not too eventful - everything came apart nicely in true BMW fashion.

As I expected, the shopping list was added to.
The clutch was original, looks like it would probably go again, but with another 100NM torque - I'm questioning it.
I saw a few single mass flywheel & clutch conversions on ebay that I quite liked the look of, a friend advised against since the gearbox will already be sweating it would be best to keep the DMF - so I ordered a replacement clutch kit (Valeo).

When unbolting the steering rack to remove the steering column/shaft - I noticed the aluminium casting had cracked and was in a few pieces where the bolt goes through, don't fancy going back on the road like that. Will hopefully find a good used item in the next few days.

I also forgot a clutch pilot bearing as the 3.0 I have was from an auto.

Time to begin transferring parts on to the 3.0 block.

IMG_2532.jpg
 

AlexGSi2000

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Mar 31, 2025
Points
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Location
Liverpool, UK
Model of Z
3
Well, as of late last night, the M54B30 is in and bolted to the mounts.

Loom is all connected as with most of the engine bay pipework.etc - nice and easy.
Flywheel & clutch bolted on.

Unfortunately the airbox I was sent was for a z4 3.0 rather than the z3 :(
I can still test run the engine with it though.

Tonight's job is to get all the underside done - gearbox, prop & exhaust, then I can try a test start fingers crossed!
Once confirmed it runs ok, I'll refit all the front end.

I also noticed upon removal of the engine that the steering rack had a cracked mount on the drivers side and was in pieces - sourced a replacement from ZBits and fitted last night.
z3111.jpg
 

AlexGSi2000

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3
Well, its in and runs.

First start was yesterday evening, which didn't fill me with confidence :whistle: - spluttering, misfiring, wouldn't hold idle and stalled a lot, a light press of the throttle stalled it - didn't have my laptop with me to read codes.etc
It got to 1am at that point, so decided to call it quits - was happy that the issues weren't mechanical / timing.

Returned today with the laptop - plethora of error codes, cleared them and none came back apart from a phantom electric cooling fan (I'm assuming the map that was flashed to the ECU is looking for one that's not there.
After clearing the codes the car is now much happier, will hold itself at idle and doesn't stall - still a slight uneven idle / miss, but nowhere near as bad as it was prior to clearing the codes / resetting adaptations.
I have a few spare parts - throttle body / idle control valve.etc so will swap them over during the week and see if it makes any difference.
The 3.0 engine I purchased pretty much had all its sensors changed for unbranded versions - so swapped the genuine BMW ones from the 2.2 - only one left to swap is the intake cam sensor which is Delphi branded.
The MAF I purchased is also a Delphi, I have a slight suspicion this may also be contributing to an uneven idle.

Anyway, at least its drivable, and what a change its made - its filled the gap I felt the car was missing. Its gone from feeling fairly lethargic to at least putting a slight doubt in your mind when putting your foot down out of a damp corner.
Covered around 15 miles so far, no complaints from the box / diff.

The only faux par I made was the clutch purchase - I was tempted to fit a solid flywheel and clutch it, but instead fitted a cheap Valeo replacement 2.2 clutch to the existing dual mass - terrible, I did have my doubts when fitting due to the clutch type compared to the standard LUK - it feels like I've fitted a paddle clutch - loads of chatter on light load / light clutch pedal depression, really need to raise the revs to try and overcome the chatter when setting off - I'm sure the box wont like me for it, so may well either buy a solid flywheel conversion, or replace it for a new LUK.

All in all, very happy with the result - now I need to get out and enjoy it.

Video;

IMG_2591.jpg
 

AlexGSi2000

Dedicated Member
Joined
Mar 31, 2025
Points
28
Location
Liverpool, UK
Model of Z
3
Should have trusted my intuition with the clutch I fitted - I've not driven the car since the test run as the clutch feels that bad.

I bit the bullet and ordered a solid flywheel conversion of eBay for £189 - not too bad a price, quality seems reasonable.

Ive taken some photos for comparison, hopefully others will agree, the Valeo kit I purchased just doesn't look "right";

From Left to right; Valeo standard replacement, Solid flywheel kit, original.

ClutchComparison.jpg


You can see the Valeo friction disc looks a little small on the original DMF;

ClutchFly.jpg


Original pressure plate on the left, Valeo on the right - you can also see the Valeo friction disc seems too small for its own pressure plate, inner ring is where it wasn't making contact.

PressurePlate.jpg


Solid kit looks much more proper;

NewClutch.jpg


Should have it buttoned all back up (again) in the next couple of evenings, then I can finally take the thing out for a drive - felt like its been a while!
 
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AlexGSi2000

Dedicated Member
Joined
Mar 31, 2025
Points
28
Location
Liverpool, UK
Model of Z
3
Gearbox, propshaft and exhaust back on after work - my word, what a difference - no judder / chatter anymore, as smooth as you like.

Took the long way home, smitten.

Cant believe how much of a difference the additional power and torque has made, it really doesn't need any more in my opinion.

Looking forward to getting some use out of it during the evenings next week.
 
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