My little project Z4 2.0 Sport..

2003 - 2009, roadster, coupe, facelift
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Ducklakeview
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My little project Z4 2.0 Sport..

Post by Ducklakeview » Tue Oct 17, 2017 8:48 pm

Thought I'd do a similar thread to Andy with his own 2.0, detailing repairs all in one place, in case people find it useful.

Ok, so I was put onto this car last week by Jamie_z4 who was considering buying it himself, but decided against it.. It's a 2008 85k Sport, 2 owners (last for 3 years) and FSH, fairly well specced with;

Half leather heated sports seats
M sport wheel
Aux in
Storage
Mats
PDS
Cupholder
Wind deflector and boot storage clips

It was advertised as having a few faults, namely a failed roof :D the dreaded 3 lights indicating a failed ABS pump, drivers door failing to unlock from remote but locking fine, and erm, a couple of dents;
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Quick phonecall to the seller, and deal done/deposit paid, and arrangements made for me to collect it yesterday.

So, 5hrs on various trains later, I arrived to see it parked in the driveway, looking a bit sorry for itself...
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So I had a thorough look over it and quickly spotted a couple more issues, namely the ubiquitous cam cover leak, and inop aircon. A quick scan with the Launch revealed the 5DF0 and 5DF1 faults, relating to the abs pump motor and it's connector, and the usual roof errors. No other fault codes though :thumbsup:


Little bit more haggling was done in my favour :) paperwork checked (lots of it, I'll come back to that later) and monies changed hands, well were transferred electronically lol.

We said our goodbyes and I went out to the car... 15 mins later, Martin came out to see why I was still there, and was surprised to see me hanging out of the boot... Yup, I decided to do the roof motor there and then, as it was 240 miles home, and I wanted it down! To say he was surprised when after another 5 mins I had it working like a dream is an understatement :evil:

So having checked the coolant level and oil via the dash, I was off - First stop the garage for fuel, and to check the tyre pressures...

So, how did it drive?

In a word, damn bloody well! It's on almost new Bridgestone runflats all round, and M Sport suspension, BUT it rides better than mine, isn't crashy over bumps and doesn't tramline one little bit, all of which surprised me. It's also slightly higher than mine, which I put down to my 224's having different offsets, and spacers up front which lower it marginally.

Anyway, almost 5hrs for the trip home, 79mph where appropriate :evil:, 51 in the SPECS zones :( and it averaged 38.5mpg, which I thought quite impressive. Ran like a sewing machine, not a hiccup, so all good..

Arrived home, just in time to go to work :cry:
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Last night I tried the BMW approved tool for testing the ABS pump;
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This resulted in the lights going off initially, but coming back on, coinciding with my theory as to the actual fault....

Had a look at the paperwork when I was at work, and JESUS, he's spent some money on it in the 3 years he's owned it.

Bill for the last MOT was over £700, including a couple of tyres, front wishbones and a service.

Interestingly, last year, again along with a £630 bill for service and MOT (2 tyres on the opposite end!) there is another receipt for circa £900 (can't remember exact amount) for ... Diagnosis of ABS fault AND a repair from BBA Reman, fitted by a third party (Halfords of all people :| ) Made a mental note to call them in the morning, as they supposedly offer a "lifetime guarantee"

More to follow...

Mike
Roof motor repairs/relocations and exhaust mods!
I can refurbish your VANOS and restore that mid-range grunt.
Contact me @ zed4mods@gmail.com

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My little project Z4 2.0 Sport..

Post by Ducklakeview » Tue Oct 17, 2017 9:13 pm

So, time to crack on....

Firstly a call to BBA Reman, only to be told they have a contract with Halfords for repair, but it's Halfords that warrant the items. Fearing the worst, I rang the Halfords branch, yup guaranteed for 12 months only... This is why I call them "Halfrauds" anyway, that was that sorted..

Up in the air you go my lovely...
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Quick interior shot, just for the hell of it...
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And off with the wheel and inner arch liner, then out with the pump..

I won't detail this bit, because TBH if you can't get that far, this isn't a job you should be doing. Anyway because it had previously been repaired, getting the motor off the pump was simply a matter of removing the "repair plates" fitted by BBA-Reman, which ironically, had warranty stickers over them! And they look like this;
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If the pump has not been apart, there are a couple of tabs that need machining off to get the motor free. When this is done, the motor simply pulls off and looks like this;
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Quick test, and yup, it was dead..
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Removed the seal;
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And levered it open;
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Which gets you to here;
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I could see that one of the brushes had seized in it's carrier, which is what I thought the fault would be! Time for a video - No comments on my tunes in the garage please!




So, back together and time for a test...




Reassembled, and back into the car. I them bled the brakes. I used my Launch to invoke the BMW diagnostic bleeding procedure, which isn't strictly necessary, BUT I wanted to give the pump a good workout, as it's used in the bleeding process.

And?

All done, error codes changed from "current" to "historic" meaning they hadn't occurred again, so cleared them.

Whilst I was under there, after chatting to Andy F, I decided to remove the CDV, I didn't take any pics but, it is a 2 min job using 2 x 17mm and 1 x 11 mm spanner. You don't need to bleed it as the clutch is fed from the brake master cylinder, so fluid starts coming out when you split the line. Just unscrew the valve (it's on the end of the flexi hose next to the slave cylinder) and screw the pipe straight into the hose end. I then opened the bleed nipple with a 6mm socket and allowed a bit of fluid out to purge any air.

I removed it as earlier today, I could actually "feel" it doing it's "job" and didn't like the "sponginess" it introduces into the drivetrain.

Wheel back on, and out for a test drive....

No lights, and ABS working as it should, tried in all modes, and it is perfect. Clutch feel is MUCH improved, and the sponginess is gone. Quick changes are much better and more fluid now.

And that's it for today, time to go to work!

Mike
Roof motor repairs/relocations and exhaust mods!
I can refurbish your VANOS and restore that mid-range grunt.
Contact me @ zed4mods@gmail.com

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My little project Z4 2.0 Sport..

Post by JINGLE » Tue Oct 17, 2017 9:50 pm

Great stuff!!

You annoy me how easy you make everything look :rofl:


Interested to see what sort of work/mods you do to the 2.0..... might be worth a trip for me if there’s some that I’m interested in :fuelfire:
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My little project Z4 2.0 Sport..

Post by Ducklakeview » Tue Oct 17, 2017 9:56 pm

JINGLE wrote:
Tue Oct 17, 2017 9:50 pm
Great stuff!!

You annoy me how easy you make everything look :rofl:


Interested to see what sort of work/mods you do to the 2.0..... might be worth a trip for me if there’s some that I’m interested in :fuelfire:
There's a fair few things on my "to do" list ATM;
  • Couple minor scratches to flat sand and polish
    Couple stone chips for same treatment
    Decontaminate paintwork and polish
    Cut and code a 2nd key
    Change cam cover gasket
    Recharge Aircon
    Dent man
And that's just the start...

Mike
Roof motor repairs/relocations and exhaust mods!
I can refurbish your VANOS and restore that mid-range grunt.
Contact me @ zed4mods@gmail.com

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My little project Z4 2.0 Sport..

Post by Mr Tidy » Tue Oct 17, 2017 9:57 pm

Looks like it's all going pretty well so far OP! :thumbsup:
Z4 3.0Si Sport - Coupe for added stiffness!
Current - Montego Blue, Pearl Grey & 108Ms. Cruise, Storage and pdc. 325ti Sport as a DD.
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My little project Z4 2.0 Sport..

Post by JINGLE » Tue Oct 17, 2017 10:09 pm

Ducklakeview wrote:
Tue Oct 17, 2017 9:56 pm
JINGLE wrote:
Tue Oct 17, 2017 9:50 pm
Great stuff!!

You annoy me how easy you make everything look :rofl:


Interested to see what sort of work/mods you do to the 2.0..... might be worth a trip for me if there’s some that I’m interested in :fuelfire:
There's a fair few things on my "to do" list ATM;
  • Couple minor scratches to flat sand and polish
    Couple stone chips for same treatment
    Decontaminate paintwork and polish
    Cut and code a 2nd key
    Change cam cover gasket
    Recharge Aircon
    Dent man
And that's just the start...

Mike
What year is it? I have a new and not fitted face lift rocker cover gasket as it turns out mine was 1 of the lasts 1s made and they refined it so I had to buy another 1.... your welcome to it and just repay a favour some day?

Think it’s febi
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My little project Z4 2.0 Sport..

Post by Ducklakeview » Tue Oct 17, 2017 10:10 pm

It's an 08 plate?

Mike
Roof motor repairs/relocations and exhaust mods!
I can refurbish your VANOS and restore that mid-range grunt.
Contact me @ zed4mods@gmail.com

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My little project Z4 2.0 Sport..

Post by JINGLE » Tue Oct 17, 2017 10:14 pm

Well I have this if it’s of any use?
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My little project Z4 2.0 Sport..

Post by Ducklakeview » Tue Oct 17, 2017 10:15 pm

JINGLE wrote:
Tue Oct 17, 2017 10:14 pm
Well I have this if it’s of any use?
Cheers m8, appreciated :)
PM?

Mike
Roof motor repairs/relocations and exhaust mods!
I can refurbish your VANOS and restore that mid-range grunt.
Contact me @ zed4mods@gmail.com

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My little project Z4 2.0 Sport..

Post by srhutch » Tue Oct 17, 2017 10:30 pm

CDV won’t make the clutch feel sponges. It only has an effect when you are taking your foot off where it restricts flow.
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My little project Z4 2.0 Sport..

Post by Ducklakeview » Tue Oct 17, 2017 10:54 pm

srhutch wrote:
Tue Oct 17, 2017 10:30 pm
CDV won’t make the clutch feel sponges. It only has an effect when you are taking your foot off where it restricts flow.
That's what I meant, soft engagement..

Mike
Roof motor repairs/relocations and exhaust mods!
I can refurbish your VANOS and restore that mid-range grunt.
Contact me @ zed4mods@gmail.com

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My little project Z4 2.0 Sport..

Post by kis » Wed Oct 18, 2017 12:28 am

Nice little project. Like Jamie said it's annoying how easy you make it look!!

Interesting comment about it feeling much better than the M54. I thought I've seen posts where you've renewed most parts? Bushes and the like? Why do you think it feels noticeably better?

Look forward to more updates! :)
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X6 - E71
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My little project Z4 2.0 Sport..

Post by enzed4 » Wed Oct 18, 2017 12:43 am

Something to get your teeth into, Mike :thumbsup: . Looking good so far. I don't see any plans for those notoriously difficult to refurb split rims. What are you hoping to do with them - refurb or replace?
Edit - also, have never seen half-leather M Sport seats, didn't know they were an option.
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My little project Z4 2.0 Sport..

Post by ph001 » Wed Oct 18, 2017 1:02 am

Awesome work and superb diy on the pump. Bravo 👏
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My little project Z4 2.0 Sport..

Post by bz4kev » Wed Oct 18, 2017 5:23 am

could not be in better hands and will make someone a great car once mike has worked his magic on it :sorcerer: :thumbsup:
2004 z4 30i auto Toledo blue stubby areo front back sideskirts and rear spoiler mfsw DLV exhaust mod 108s refurbed ram air scoop E46 M3 seats clear rear lights m sport black grills

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