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Unread 08-31-2015, 07:38 PM
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Fair! Fair! is offline
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Join Date: Jul 2004
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Default Re: 2002 BMW E46 325Ci - Daily/Track Car - Project Jack Daniels

continued from above

WINDOW SWITCH REPAIR

Now that the cooling system works we could concentrate on the last few "emergency" repairs and turn the car over to Amy to start daily driving (so she can point out what else is broken). We already know the suspension is pretty much shot; It needs lots of suspension bushings, a rear subframe reinforcement/subframe and bushings, new dampers, the top mounts are shot, etc. But one thing that was broken that couldn't be ignored were the power window switches... 3 of the 4 switches were busted. Did that mean the window regulators were also broken? Another gamble...



Both the left and ride side window switches (above left) had one or more broken "tabs", so the windows wouldn't go up or down. Luckily the "endurance car" ('99 328i) is getting all of the OEM door and rear glass replaced (with fixed Lexan), so I borrowed that car's console mounted window switches (below left) temporarily to test and see if this 325's window regulators even worked. This is a super easy job: pop the leather shift boot up (see above right), then unscrew two Phillips screws at the back, and the shift cover comes out for easy access.



The E46 sedan has the same passenger side window switch, which popped right into the slot in the shift cover and plugged into the wiring harness. Both the right side door and rear quarter glass power action worked, whew. The driver's side switch also plugged in and everything again worked, but the "child lock" button for the rear window control lock-outs (not included on the Coupe) makes the switch housing too long to fit the slot on the Coupe's shifter cover (below right).


Left: The switches are held in "hook" at one end and snap into the other end. Right: The left side Sedan window switch is too long

As you can see (below) the replacement window switches aren't expensive, and this is a super common thing to be broken on an E46 - the little individual window switch "paddles" snap and break off. I found some under the seat when we swapped that out (below).


After I tested that the two door windows and two rear quarter windows worked with the borrowed E46 Sedan window switches, we ordered the correct switch for the driver's side for an E46 Coupe. There's a third variation for the Convertible as well. Confused yet? Welcome to German cars.



The correct part (BMW p/n: 61316902175) showed up a few hours later from our BMW dealer. I then popped the cover out again and swapped in the correct switch, for a completed job with the right parts. This is a 5-10 minute job at most, and we spent less than $45 to fix it. Easy.

DRIVER'S SIDE POWER SEAT REPLACEMENT

This car was a Premium car, with Harmon Kardon stereo and power leather seats on both sides - when new this was a high end car, but time takes it's toll. Both front seats were both torn/worn/ripped at a couple of leather seams, and the fore-aft power actuator on the driver's seat was broken. Luckily the seat was stuck where it fit my driving position (so Olof and I could do our initial test drives to prove the cooling system repairs) but it didn't fit Amy, so she couldn't drive it.


The worst part of Jack Daniel's interior are the shift handle (see pic above), front seats (torn) and the steering wheel cover (worn).

Long term plans include installing two fixed back racing seats with a driver's side slider, and make it fit Amy's driving position perfectly. The seating position really makes or breaks a track car for her. With too many unknowns left to check on this car before we go dumping expensive racing seats into it, for the short term I once again borrowed parts from the Endurance car car. The power front drivers seat from the 99 328i Sedan was pretty ugly but the power actuators all worked, so I just had hoped it would fit the Coupe...


Reduce. Recycle. Re-use. We're keeping it green on Jack Daniels by "borrowing" the front seat from the 328i

The stock seats in the Sedan were in pretty rough shape but I just wanted something functional to use temporarily until I could either find some NICE black leather factory E46 seats or until I could convince Amy to just let me install some of the dozen or so racing seats sitting in our lobby... She's thinking "daily driver" while I'm always thinking "race car", heh.

Since the 325's driver's side power seat was dead, the seat was "stuck" in a weird spot. This made access to the old seat's 4 mounting bolts tricky. The front bolts were easy to get out but the rears were half covered up, but Olof fought it and got it unbolted, then we tossed the dead seat out back. The recyclers grabbed it before I had a chance to weigh it, but its one heavy mug. We will weigh the Sedan's power seat when we take it out next time.



Oh there was some nasty junk hidden under that seat (retch!)... sticky coins, a dirty comb, fossilized french fries, plus all sorts of crumbs and soda spills. Olof got all of the left side carpets vacuumed and shampoo'd quickly and it looked 100 times better. The other side was strangely clean and Amy vacuumed that side out a few days later, when I cleaned all of the leather, vinyl and plastics on the weekend.


The 328i Sedan seat is ugly (grey) but the power functions works, so its being used for now

The '99 328i Sedan driver's power seat bolted in easily enough. The plug for the seat was correct and everything worked, but its now throwing a "seat belt" code, so there must be a wiring difference internally. It does not have the "tilt forward and up" back seat access feature of the Coupe's front seats, but oh well. The ugly gray leather Sedan seat will work for now, as all power functions operate, but its temporary. We will get race seats in here...


These are the Cobra seats and Momo wheel we used in the '01 330Ci, and they are what we will likely use in this 325Ci... soon?

All told this seat swap and half carpet clean-up took about 0.5 hours and cost $0 in parts (borrowed seat).

WHAT'S NEXT?

If you've read one of my many build posts you know its wrapping up when you see that subtitle. I like to give clues to what mods we have in store next time. Here are the highlights.

This 325Ci needs new headlights to pass inspection, as the original units were both damaged in a light front end hit at some point. The housings are all busted up, the lenses are cloudy, and they are held in with bailing wire. I have done a LOT of looking (there are a lot of variations between the Coupe/Sedan/M3, with pre-facelift and post-facelift for the coupe and sedan) and found some ~$200/pair OEM looking halogen projector style light assemblies, which I have on order. Will get those in the car pretty soon, then try to chase down the last CEL (Cam Sensor is a common flaw on the M54) so it will hopefully pass inspection.


Ryan made custom full length headers for this LS3 V8 in a tick over two days... why not make a better E46 header than what eBay sells?

After that we need to tackle the exhaust, as the rear muffler hanger is gone and it has a good exhaust leak behind one catalyst in one manifold assembly. I really DO NOT want to buy $800+ worth of factory style replacement manifolds/catalysts, so we might fabricate something there. I'm most definitely NOT buying the crappy eBay header for this car, like the blue 330Ci got (two sets were purchased for that car, to get something that fit). Should we make a new, proper full length header for the M54? Is there a market for this, when the $100 eBay junk has been the standard for some time? I'm going to do a business case for this and see - it wouldn't be that hard to make, with our in-house fabricators.



Once we determine the header solution, the after-header exhaust will be custom made from 3" stainless tubing and Magnaflow mufflers and cats, when it gets replaced. We've done a system like this before (blue '01 330Ci syste, shown above) but since then we had a development break-through and have picked up BIG numbers while becoming quieter. There's a muffler from Magnaflow that made that happen, along with an unusual routing. We could see if that worked on this car, with the full length header. Very tempting, and it could make for a new product - which is why I pushed Amy towards another E46 in the first place. This car has to DO WORK FOR VORSHLAG.


One possible track setup is this 18x10" wheel + 265/35/18, which we did to the '01 330Ci (pre-flares)

Replacing the wheels and tires are a VERY high priority, and as I mentioned above I hate the Foose wheels with a passion, and after Amy's first long test drive one of the tires got really low on air pressure. I'm looking at 17x9.5" Forgestar F14s for street wheel set first (see below), with a better offset made exclusively for the E46 non-M - with no spacers needed. We have done 18x9 and even 18x10 (above) before, but they all needed spacers and the 10's needed LOTS of fender rolling and camber to fit. Even then we were limited to 265s on the rear, until we flared the 330. We'll tackle something similar for track use (depending on which class we go to, which might limit tire choices/mod points). This car has a base NASA TT class of TTF, so we still have a lot of "mod points" to play with in TTD or TTE.



The various body dings and scratches will all be addressed in good time. This 325 also needs a new front bumper cover, hood, and rear bumper cover - and we will see if we have class points to do M3 bits for the front and rear. The old brakes are also shot. Depending on NASA classing points, we might steal parts off of my white 2001 330Ci in the shop and use them on this car: the hood, bumper covers, even the larger 330 brakes would take only a few hours to swap over. We'll see how the class build shakes out - there's a couple of ways we can go for a TTE or even TTD build.


This was a weight we took with low fuel but the full sized spare, jack and other trunk junk were still in place

Last but not least, no build thread of mine would be complete without the initial weighing! We were in a hurry so we didn't take out the spare wheel/tire or the jack. This porker came in at 3256 pounds, but considering the trunk junk and what these Foose anchors weigh, I shouldn't be surprised. We will knock the weight down by around 200 pounds, I can assure you of that. (base classing: BMW 325 ('01-'06) (2.5L184 hp) = TTF**, min wt 3197 pounds w/ driver) This 325Ci one will be kept for a while, and Amy is already driving it to work, so we will have some fun with this one. Check back next time to see a few more repairs and hopefully some upgrades!

HOURS & COSTS SPREADSHEET

As a former mechanical engineer and project manager before I started Vorshlag, I used spreadsheets every day. Some habits die hard. When I was writing the second set of posts for this forum build I went ahead and broke down the costs and hours spent on each round of work. These are normal street prices for the parts we used, in the brands we prefer, but I supposed you can hunt long enough and find a better deal. The hours are logged in our MSA system and are accurate.



In this little spreadsheet you can see hours spent, the actual cost I paid for the car (with Tax), and the approximate prices for the parts used in this First Round of mods. I will do this for each round of mods and keep a running tally for the total dollars spent - so you readers can see what the real costs are for owning a high mileage E46 Coupe, as well as prep costs for a NASA TT build.

Cheers,

Last edited by Fair!; 09-10-2015 at 09:35 AM.
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