22 January 2016

Stoopid Washer Tank

When I got the car, the washer tank was dry.  It was also missing the interior strainer that goes inside the top of the tank to keep debris out.  I replaced the strainer.  Great.  Eventually I got around to getting a gallon of fluid thinking "this is great.  Here is a super-easy mod for me.  Just pour the fluid into the tank and we're done".  Not so, porkchop.  I put the fluid in and then I heard a significant leak running out onto the garage floor.  Sooner or later I will get a "cake" mod/fix, but this wasn't to be it.

The washer pump had a crack or failure in the diaphragm of the check valve.  Ok.  Need a new washer pump.  If I am doing that, might as well replace the whole tank and make the engine bay look new again.

I have been unable to locate the correct part number for the washer tank cap.  I have been unable to locate the correct part number for the seal that goes around the washer pump/washer tank interface (I thought it was 61661365657).  If you find these, please comment on this post.  The numbers listed at realoem will get you the wrong parts!

Washer pump, 67128377987, $79.31r
Washer tank, 61608383546, $49.12r
New washer fluid, about $3r from wherever.

Total cost of this mod = $128.43r
Total investment in vehicle to date = $7636.93

New washer pump
Old tank on left, new tank on right.  Cap is sad and ass-colored no matter what.
Neither of these 2 part numbers will work.

Door Improvements

The windows on the car are slow going up and down.  I knew I was going to open the door panels and service the sliders, so might as well knock out a few other improvements at the same time.  As previously noted, this car came with black plastic interior door pulls.  The chrome now only have a nicer look, but they are heavier and more fitting of the coupe's nature.  I removed and replaced all 4 of the window sliders, as well as cleaned out all of the old grease and replaced everything with Superlube.  I also replaced the stock midrange speaker with a JL tweeter, part of the C5 component system that is partly installed now.  The JL tweeter perfectly replaced (and I mean PERFECTLY fit, the HK midrange.  The JL woofers I put into the kick panels did not fit perfectly, I had to cut away some material on the aluminum baskets/frames to match the factory bolt pattern.  This was disappointing, as the woofers from the Alpine 5-1/4 component system I used in the rear fit exactly right.  The butyl tape on the insulation had hardened, so I replaced all of it with new and also repaired any punctures and tears in the foam insulation with metalized thermal tape.

Window sliders, set of 4, 51321938884, $3.57r
JL Audio C5-525 Component Speaker System, $499.95r
Chrome interior door pull R, 51222261150, $60.65r
Chrome interior door pull L, 51222261149, $60.65r
Side airbag plaque, left = 51418413215, right = 51418413216, $3.62r each
Mirror blank, 51411903734, $18.66r
Door panel clips, replaced all with new,  X per door needed, 51411973500, $0.42r each, need 14 to do both doors
Butyl tape for door panel insulation liners, already bought and used on windshield cowl replacement  UPDATE 3/30/16:  Do not use this product on the vapor barriers!!! Total cost of this mod = $656.60
Total investment in vehicle to date = $7508.50

New parts

Forwards slider position (black channel) and really old door insulation seal

Forward door slider, locking pin

Aft door slider, side airbag removed

HK midrange on the right, JL tweeter on the left.

New 3M Window Weld installed.

OEM BMW Alarm Keyless System and Footwell Light Kit

Sadly, you can no longer buy the factory BMW alarm for Z3 cars, part number 82111470403.  I had to buy a used one on ebay.  It came with one remote, and that remote did not work with the alarm right out of the box.  I bought a second remote on ebay, also used, and programmed them both to the alarm unit I had.  To program the 2 fobs to this particular alarm "head unit", I followed this guide from mcoupebuyersguide and also it's listed in the original BMW alarm instructions/owner's manual.  To keep the car fresh, I also installed new alarm fob covers which I bought on ebay.  2 covers with new buttons and new batteries included was $17.95.  They don't say BMW on them, but the plastic is new and they aren't worn and shiny any more.  I was able to locate the original alarm owner's manual here and print a PDF for my 3-ring binder.

In the process of installing the alarm, I discovered the hood switch had failed so I replaced it.  Once the hood switch was replaced, the alarm would chirp but would not arm.  So something was still "open".  The door switches work, the hatch and hood switches work, so the only other possibility was the radio switch.  Behind the radio there is a switch that closes if you remove the radio (people used to steal car radios... does that happen any more?).  When I got the car, the radio was already slightly canted out at the bottom which bothered me and was on my list of things to perfect.  So better now than later.  I removed the radio, replaced the switch, and now it sits perfectly flush and proper.  And the alarm works.

While I had the glovebox out, I removed the steel reinforcement panel in the door to make it lighter weight and less likely to sag.  I had previously removed the driver's side knee crash protection too, in order to make trim panel disassembly easier.  I did have an old anti-sag glovebox reinforcement plate in stock, so I put that on too.  The striker panel trim inside the glovebox was cracked, so I replaced it with a new part.  The individual parts of the glovebox all have separate part numbers, which is nice for repairs. 

Also while the box was out, I installed a LeatherZ Footwell Light kit.  We have sold hundreds of these over the years and they are a really nice mod.  The Z3 was always lacking in some of the basic E36 features, especially when it comes to accessory lighting.  When I was installing the footwell light kit, I also noticed the driver's dead pedal had a small crack at the very inner corner.  I reinforced this point with fiberglass tape and many layers of epoxy.

Used BMW Alarm, ebay, $125.00r
LeatherZ Footwell Light Kit, $65.00r
Second BMW alarm fob, used, ebay, $59.95r
2 new alarm fob covers and new batteries, ebay, $17.95r
Hood switch, 61319119052, $44.82r
Radio switch, 65758366215, $35.20r
Glovebox striker plate, 51168410477, $11.66r

Total cost of this mod = $359.58r
Total investment in vehicle to date = $6851.90

LeatherZ footwell light kit

Alarm/keyless fobs in new aftermarket cases

The correct alarm for the Z3 is the one on the right that ends in part number '925'.  The '445' is identical except it has the glass breakage microphone integrated into the base unit.  The Z3/925 unit has a female jack for an external microphone for it.  I think either would probably work in the car.  I don't have an external mic for my alarm yet but I am looking for one.

You can see the teat on the right has been over-stressed and is bent.  This prevented the radio from sitting right in the console and prevented the radio switch from working properly.
Radio switches.  Bent is on the left (now clocked 180 from the previous pic) and new is on the right.

Reinforcements on the inner corner of the dead pedal

Tiny crack in corner of dead pedal... will see if the fix works.

New hood switch.
Blue/yellow loom will run the alarm LED, which will mount into the new, not-installed electrochroamatic auto-dimming MY 2000 rear view mirror.

Gas Cap Details

The lanyard to the gas cap was missing as noted previously.  It's not available as a separate part.  Since my cap is keyed to the ignition key, I want to avoid completely replacing it if I can.  So I bought a new cap (non-locking version, same as what is on my S54) and took the new lanyard from it, keeping the cap for future S54 use.  While I was at it, I replaced the gas cap gasket with an E30 part I learned about on one of the Z3 forums.  Fits well and should keep a good seal.

Gas cap with lanyard, 16116754492, $28.55r
Gask cap gasket, 16111179680, $8.78r

Total cost of this mod = $37.33r
Total investment in vehicle to date = $6492.32