College car rebuild - 1996 BMW Z3

I always wondered why they didn't put a little bigger engine in it, like a 2.4 straight six or something. But I bet BMW tuned that 1.9 super good, and it's light so it'd be fun af.

 

It's basically a stroked 1.8 out of the 318. They only offered the 1.9 for a few years before moving to a slightly larger displacement wise straight 6.

I've been looking into swapping in the 3.2 that is in the MRoadster/M3 and forced induction options for the 1.9. First step is dialing in the suspension and upgrading the brakes, then I may get more serious about bumping the HP. The 1.9 is light and reliable and I can get more than the inline 6 in terms of power with less weight over the front of the car with a supercharger...just won't have the sweet NA sounds. I've also looked into ITBs but the HP bump isn't as significant as a blower.

 

Interior is mostly back together now. I still have the steering column apart because I need to sort out the wiring harness for the horn but the shift boot and brake boot/handle are back on now.

Ignore the dirty interior...I've been driving it and it's had the top down in our dusty garage since March.

 

Started feeling out how much work the paint correction is going to be. I'm not going to show car mirror finish, just want to clean up the scratches and not get super aggressive.



Here's the before


This is after about 45 minutes of work

 

Been busy the past few days pulling the suspension to get ready for all new bushings, ball joints, koni shocks/struts, H&R springs, subframe mounts, rear diff mount, and stainless steel brake and clutch lines.




In hindsight, I should have replaced the shock mounts before installing the rollbar and new top because the bar was definitely blocking easy access to the mounts. The new shock mounts will be accessible from the wheel wells so future servicing will be easier.



Tomorrow I need to go buy a swivel for the ratchet so I can get to the last bolt on the front LCAs.



I have a few more parts I'm waiting on that should be here Friday so once I'm done removing all the old suspension bits I'm going to focus on some electrical repairs after a rat got under the hood and chewed up a bunch of wiring. Fortunately I was able to fine a complete harness for the injectors so I just need to pull the intake manifold to replace it all. Once that is done I have a couple wires on the MAF that I need to repair. While the manifold is off I'm planning to replace some of the coolant pieces that are difficult to get to with the manifold on.

 

Homemade tools FTW...sleeved a 3/8 threaded rod and am using washers to push out the old trailing arm bushings

 

Car is back on the ground with new poly subframe bushings, differential bushing, and rear trailing arm bushings in the rear. The front has new control arms and poly lower control arm bushings along with new inner and outer tie rod ends. I installed koni adjustable struts/shocks and H&R springs that lower the car about 1.25/1.5" from stock.

Had to get creative removing the subframe and differential bushings. I cut the center out of the differential bushing and pressed it out with a bearing press.





I took a similar approach on the subframe bushings but also cut the metal sleeve. First I had to drill out the center then I went after the sleeve with a reciprocating saw, making a point to stop cutting before hitting the subframe. After a quick pry on the cut piece they pressed out easily using the bearing press to get them started and then a socket and hammer to finish.










Once the car was back on the ground I started on the removal of the rat chewed wiring harness. Fortunately I was able to get to everything without removing the lower intake manifold, saving time and avoiding having to disconnect the fuel line.



I'm looking forward to a new garage that is tighter to keep rats out. I decided to keep the chewed harness incase I need to patch the replacement at some point.



Waiting on a couple hose crimps that I had to order and the depinning tool. Once I get the MAF plug depinned I will be able to measure and order the replacement pins. Goal is to have it sorted so I can go for a drive on my birthday in a few weeks.



I'm hoping next year I'll be ready to start ordering parts to install a supercharger off the mini cooper with a goal of to 275 to the wheels and minimal additional weight for M Roadster power in a lighter weight package. Brakes, regear, cooling system refresh, and subframe reinforcement on the project list first though.

On the MAF sensor, I ordered the tool to depin the plug with the plan being to just cut 3/4" off the factory wires and avoid a crimp or soldered joint

 

Car is back together. Fresh tires mounted on new forged wheels...just in time for top down driving weather.