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Discussion Starter · #1 · (Edited)
MasterC17's 2005 330Ci ZHP Project Build

Background:

Basically, I was looking to purchase an 01-03 330Ci. Needed to be a manual, with ~55k miles, good colors, and mostly a good price (max about $12,500). I started my search around two months ago and I looked at a few cars during that time frame but none worked out (one was an automatic, etc. etc.).

And one day I found a salvage, wrecked 2005 330Ci ZHP. It was perfect, colors were great, 6-Speed Manual, Cold Weather, 54k Miles, etc. :thumbsup: Now, obviously this was going to be a risk and I didn't want to end up with a bunch of money in the car. In the end I bid what I believed it was worth to me and I got it! Within a week I had sent the money to the dealer and was ready to go pick up the car.

The Pickup:

The car was located near Philidelphia, PA, and I am close to Boston, MA. Yesterday (day after Thanksgiving), my father and I loaded up and set off to get the car. It took us almost exactly five hours to get down there and we arrived at 10 in the morning. We checked the car over quickly, it was just as we expected with no surprises.

Next, we picked up the U-Haul trailer (had to buy a ball and different wiring...:banghead:) And we headed back to the dealer. Once there we loaded up (that was a hell of a time :eek:). And lastly, I signed the Bill of Sale, got the the Title, etc. and off we went. It took about six hours to get home, and we got back around 5:30. At that point we were both done for the day.

The Project:

Basically, I want to complete my car within two months at a reasonable price. All parts will be Factory, OEM (not from the stealership though :p) Most all of the work will be done by myself (except the inner fender work and paint). Overall I want to make the car look just as it did BEFORE the accident while spending a reasonable amount all with factory parts. The work will be high-quality and it should be as if it had never been hit at all.

Phase I: Breakdown:

Today, we went in and unloaded in the morning. Here is how the car was right after we pulled it off the trailer and into one our bay's: (sorry, first set of pics are crappy):facepalm:









The damage on the car is pictured, and is contained to the front of the car :).

Step I: Remove Hood:
Very simple, one hood shock is blown, the other is intact. All wiring, insert, and even the emblem (amazingly) are good. Hood, not so much.




Step II: Remove Headlight & Misc:

Left Xenon is near-perfect, top two clips broken but can be repaired. Removed other little things before the bumper.



Step III: Remove Front Bumper:

The bumper is suprisingly intact, the reinforcement is just barely bent, so really the only bad part is the bumper cover. Grille insert is good as well.




Step IV: Remove Radiator Support:

The radiator support came off pretty easily, but as you can see it is mangled.



And this is how the car stands now:




The really GOOD part is that the frame rail is perfect, no bending or likewise at all!



Here's some close ups of the body damage:




And that is what was accomplished today, I will update as progress is made. :hi: Next step is to purchase a Radiator!
 

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Discussion Starter · #14 ·
You can buy the fender apron from the strut tower forward. And you can buy the fender support(the part the fender bolts to) from the cowl forward. A straight forward repair. Even though the frame rails look good, have a body shop measure it ti be sure. Money spent here is money VERY well spent when you go to put the car back together. I think that this is the ideal builder car, good pick. Even if you send it out to get the inner apron replaced/repaired,measured, and painted, you will come out smelling like a rose. Don't be afraid to get used parts for it. On a newer car like this, there should be plenty of good used parts for it. Just don't get after market sheet metal!! But it sounds like you know that already. Good job!!
Thanks for the advice, I was planning on getting the support and the cowl. Also, I'm going to have a body shop line everything up correctly. I'll be calling a few junk yards to try to find parts.

Good luck with the rebuild. Keep us posted on your progress. I can't believe they totaled that car. Did the air bags deploy? :thumbsup:
Actually, the driver's airbag did deploy, but the pasenger and side airbags did not, so it was a pretty light hit.
 

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Discussion Starter · #15 · (Edited)
MasterC17's 2005 330Ci ZHP Project Build 11/29/09

Phase I: Breakdown: (Continued)

Step V: Remove Belly Pan:

Removing the belly pan was a breeze, but there was a lot of broken stuff on it.



Got out all the intact parts and vaccumed up the rest.



Step VI: Remove Radiator:

Removing the radiator was a pain in the arse, and we had to clip the connector to the coiling coil. :facepalm: The radiator still had coolant in it and it and the steering pump still had oil and both went EVERYWHERE. We cleaned it up and it's done leaking now :).




Step VII: Remove Intake:

Hadn't planned on this but found out that the intake is shot. Got a big crack in it. Only good thing is I can order a Dinan one now :woot:



Step VIII: Remove Airbag:

Well, I tried to remove the airbag. I got it out, except the wires won't disconnect. On further inspection, the clips on the wires actually MELTED into the plastic (I assume from the airbag explosion on deployment). For now, the airbag will sit there.



Phase II: Inspection:

I already found out most of the problems, etc. but there were still little things to be found.

Step I: Right Door:

The right door is perfect, except for a little scrape right next to where the fender would have been.



Fortuanetly, this didn't effect the structure at all and the door lines up and open/closes perfectly.



Step II: Right Fender:

Obviously, it is gonzo. Good part is the wire for the turn signal is good and so is the turn signal itself!



Step III: Front:

Once everything else was removed, I inspected the front and there is nothing wrong :). Every bit of damage here was contained in front of the engine.



Step IV: Left Fender:

The left fender is good although it was tweaked a teeny bit. Looks suspicously like someone meant to do it...



Step V: Left Door:

The left door is perfect, and the door lines up and opens/closes good :)



Step VI: Few Other Things:

1. The windshield is cracked although I already knew that.

(Picture makes it look worse than it is)


2. The ground wiring was cut in one spot by the fender on impact, but we bent the fender back and are going to splice the ground that was cut back together soon.



3. This thingy broke (haven't taken time to fiqure out what it is yet). And the A/C Drier line is tweaked but looks like it can be shaped back to normal.



The Good:

Ballast's for Right Xenon, Right Turn Signal, Carpets in the trunk. :craig:

Overall:

A little more than I had anticipated, but that is to be expected in a wreck. Overall it was a very light hit that was on the borderline of a total loss or not.

Will continue to post as I make progress. Calling a few Junkyards tommorow to see if they got any E46's!

Interior Picture:

Just wanted to show a picture of the interior, sorry for the bad quality.

 

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Discussion Starter · #22 ·
Plug up those A.C. lines Mister! Don't want ANYTHING to get in there. You will want part number 3 and 4.I'ts very common for the plugs to the airbag to be melted.You will need the bag as well as a clock spring.The left fender being pushed out like that is an indication that the front end is pushed over,no big deal, this is why is suggested to get it measured.

If I can help answer questions for you,just ask or pm me! Happy to help.
Thanks BodyMan, I plugged up the A/C lines yesterday. I'm going to order number's 3 & 4 within a week probably, but I want to get a working radiator set-up in there first so the car runs and drives. I actually think for the airbag the clock spring is fine (didn't melt), the wires melted into the metal part of the airbag itself. So, I'm going to see if I can disconnect the wires from the clock spring rather than the airbag. It does seem like it got pushed over a bit, I'll be sure to have the body shop measure everything. Thanks!

If you are able to locate any Junkyards around Boston with E46's in them please let me know! Cool project, where in MA are you located?
Hey, I'm located a couple towns over from Worcester. I called a few junkyards and they didn't have any E46's. :bawling: Oh well.

For now I'm going to locate the best price on a radiator & A/C set-up and get that ordered. After that, I'll be getting the radiator support and number's 3 & 4 for the inner fender.
 

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Discussion Starter · #24 ·
Tonight I ordered a New Behr A/C Condenser (64538377614).

Also have pending deal's on a Used Radiator Expansion Tank (17137787039) and a New L&R Modine Radiator (17119071518).

Tommorow I'm planning on ordering the following (All New):

Radiator Support - 51717111691
Right Radiator Mounts - 17111436249 & 17117530254
Cooling Coil - 17111436262
Vacuum Control Valve - 11727553066

Unfortuanetly I got this all together too late in the week so probably nothing new for this weekend. Next weekend though it'll all be going in! Will continue to keep this updated.
 

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Discussion Starter · #28 ·
This looks awfully familiar. :rofl:

What are you planning on doing with the fender support and wheel well?

Good luck on the project. :hi:
What's that supposed to mean lol?

If you look at BodyMan's post in the first page w/ the diagram from realoem than you can see I'll be ording 3 & 4. I'm going to see if the body shop can save number 3 as it's not too bad and I would rather keep the original parts on the car. Number 4 is definitely going to be replaced though.
 

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Discussion Starter · #31 · (Edited)
Where are you ordering your parts from? I hope you at least took a look at the two links I provided, getting all this stuff from Joe Dealer would be :eek:
Don't worry I looked at both Tischer and Turner. Fortuanetly, I have a connection with a dealer that allows me to get the same prices as Tischer, but I don't have to bother w/ shipping, waiting, etc so it was the easiest thing to do. Thanks anyway :thanks:

P.S. I didn't order the Condenser or Radiator from the dealer that would have been :eek:
 

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Discussion Starter · #33 ·
Nothing much new to report but here goes:

Order Batch #1:

Ordered on Thursday, December 3, 2009.

A/C Condenser - 64538377614
Radiator - 17119071518
Right Side Radiator Mounts - 17111436249 & 17117530254
Cooling Coil - 17111436262
Vacuum Control Valve - 11727553066
Radiator Expansion Tank - 17117573781

I got the Radiator Mounts, VCV, & Cooling Coil on Saturday.

Installed VCV & stuck the Cooling Coil on for no particular reason lol.





I skipped ordering the Radiator Support for now as it would be useless.

The rest of the parts I ordered should be in Thursday, December 10 and I'll probably install the radiator the same day.

Saturday I'm taking her down to the Body Shop and they're going to be doing a front end pull and will repair/install the inner fender.

I'll probably order the Radiator Support and Inner Fender parts next Saturday as well once I know exactly what I need.

From the rear you can't even tell there's damage! :)



I can't wait to drive it!!!! :woot:
 

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Discussion Starter · #34 ·
Body Work

Well I got the car down to the Body Shop Friday and ordered the parts I needed as well (Parts 3 & 4 on Diagram) #41148238048 & 41118234044.

I also recieved the New BEHR Condenser, New Factory Radiator, and Used Factory Expansion Tank.

I also bought a Used Factory Right Xenon Headlight will be here later this week.

Here's pictures of the parts:




Car Down at the Body Shop! :woot:






The Body Shop removed the Windshield so they could have better access to the upper fender. Looks like I'll be ordering a windshield sooner than I thought; oh well. :)
 

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Discussion Starter · #38 ·
Well, got the car back from the body shop! I should have updated this a few days ago, but never got around to it.

I'm going down later this afternoon to do more work to the car and I'll post either tonight or tommorow with that stuff.

Recieved Parts:

Used Factory Right Xenon Headlight (63127165952):



New Factory Seatbelt Tensioner (72119119551):



New Factory Radiator Support (51717111691)

Body Work:

Here's some crappy cell phone pictures in the middle of the work:











And this is how it looked right before I brought it back:













Again, I'll have updated pictures tonight or tommorow :)

Enjoy! :hi:
 

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Discussion Starter · #41 ·
Get those rusted bolts on the thermostat replaced while you have easy access. Those little bugger might snap on you. Those are the result of steam corrosion. Either the gasket for the water pump or for the thermostat should be replaced to stop the escaping steam..
Thank you, but you have not experienced New England winter's, lol. The corrosion there is a result of New England, I checked and there's no escaping steam.

Nonetheless, I will probably replace the rusted bolts because I don't want them snapping on me. :)
 

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Discussion Starter · #42 ·
Re-Build:​

1. Replaced Bad Battery w/ an Everstart Maxx 94RN. Bolted right in, no modifications neccessary, much better fit than a Duralast 49DL and only $75.



2. Transfer Radiator Components that are still intact.



New Expansion Tank:



Basically all done!





3. Install Radiator & Remove Radiator Support




4. Clean Engine Bay, Connect All Radiator Components, and Threw on Front Bumper for no good reason.



Here's Some Close-Ups of the Body Work:





5. Put in Radiator Coolant, Bled, & Started Her Up with no Trouble!! VIDEO!

http://www.youtube.com/watch?v=bo0OjNQNBZQ

New Parts Ordered:

That's basically what I got done today, although it was a lot more work than it looks. I ordered a bunch of little parts I'm missing. Also ordered:

Washer Fluid Reservoir Tank (61667007970)
Headlight Tab Repair Kit (63126947822)
Headlight Lower Bracket 63126934747)
Liscense Plate Cover (51118245103)
Pressure Hose Evaporator to Drier (64536908908)
Two Hood Release/Locks (51238203859)

All will be here on Tuesday at which point I hope to have a hood and I may have a new windshield installed on Monday.

That's all for now! :hi:
 

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Discussion Starter · #46 ·
way to save a zhp from the junkyard!!

great project and glad its being done right!! oem is the only way
I'm happy to save a beautiful ZHP :)

I agree, OEM is the only way to go, when I'm done with the car I want it to be as if it had never been hit, just happened to have the cooling system, right fender, and windshield replaced :shhh:lol

And the cooling system isn't a bad thing to replace anyway! :thumbsup:
 

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Discussion Starter · #49 ·
wow man, major props to u, cant wait for the outcome (although its gonna look like a stock zhp but seeing it get back there is gonna be great!)
:nono: Not so fast! I have a little surprise in store for the hood, if I can get it how I'm imagining it, it'll be quite awesome!

My car has exactly the same (54247) Miles as yours. Nice work so far!
That's prety weird :eek: but really cool! Thanks for the compliment :)
 

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Discussion Starter · #55 ·
Wow, great work!

Would you mind telling me how you found the car?
eBay is your friend :shhh:

Nice! Satisfying to put pieces back on the car and watch the warning lights slowly go away, isn't it. :rofl:

Only thing you'll need to have reset will be the airbag light, which doesn't go away on its own.
It is satisfying to watch the lights go away :craig:

Do you mind telling me how to get the airbag reset? Thanks!
 

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Discussion Starter · #59 ·
Not so sure; I think you may have to get a whole new SRS module (or get yours "reset" by a specialty company). I'm in the process of replacing mine for different reasons (module failure, no crash), and most of what I've read says that the SRS unit is pretty much a one-time part, since it permanently stores crash data and needs to be replaced after (front) airbag deployment.
Hmmm, I thought that the SRS Module was good for three (3) accidents/airbag deployments? Of course, if someone set's their airbags off three times they probably shouldn't be driving :lmao:
 
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