2006 ZCP (Clubsport/OEM+) Build Journal

[cornerbalanced]

After months of searching, I finally found an E46 that met all of my (extremely narrow) criteria. Many told me I would never find such a spec, much less within the confines of my budget, but I got lucky. A friend sent me a craigslist link to the car early in the week and that weekend I was on a flight from LAX to Sacramento to purchase it after much back and forth with the seller (he received far more interest than anticipated and was unsure as to how he should proceed with the listing).

Factory Specs

• Interlagos Blue
• Black Interior, manual seats
• Competition Package
• Heated Seats
• Xenon Lights
• …no further options.

Updated 12/08:

Maintenance

VANOS

• New old-stock OE VANOS unit
• New OE Oil Pump Disc
• Beisan Hub
• Lang Racing cam bolts
• Hack Engineering VANOS line
• VANOS housing gasket
• Chain guides (Beisan upgraded and OE)
• Valve cover gasket
• Coil packs
• Spark plugs
• Spark plug tube gaskets
• Fuel injectors cleaned and flow tested
• Fuel injector o-rings
• Valve adjustment

Rod Bearings

• ACL “Race” rod bearings
• ARP rod bolts
• Oil pan gasket
• Oil pump pickup tube o-ring

Engine Reseal/Maintenance

• Front timing cover gasket
• Front crankshaft seal
• Rear main seal
• Intake boot gasket rings
• Throttle body o-rings
• SAP gasket
• Timing chain tensioner seal
• Cam sensor and crank sensor o-rings
• Fuel rail o-rings
• Oil filter housing gasket
• Oil pressure switch
• Drive belt idler pulley
• Accessory belt tensioner kit
• A/C belt tensioner
• A/C and accessory belts
• OE alternator (PO)
• Mahle fuel filter
• Mahle engine air filter
• Intake MAF sensor
• TPS sensor above oil filter housing

Cooling system

• Koyo radiator (PO)
• Fan clutch
• Fan
• Water pump
• Thermostat
• Radiator hoses
• Auxiliary fan switch
• Upgraded viton cooling system o-ring kit

Transmission

• Shifter carrier cup
• Clutch Pivot Fork
• Clutch Pilot Bearing
• Clutch Release Arm Spring
• Steel (upgraded) Clutch Fork Pivot
• OE LUK Clutch
• Pilot bearing
• OE Flywheel and bolts (PO)
• Shifter rebuilt, OE, E60 leaver (PO)

Bushings

• OE front control arm bushings
• OE front control arm housings
• OE Engine mounts
• OE Transmission mounts
• OE Steering coupler
• OE Guibo (PO)
• OE Center Support Bearing (PO)
• OE Butyl CSB tape
• OE diff mounts and hardware (PO)
• OE Differential cover (PO)
• Lemforder rear control arms (PO)
• AKG 95A subframe bushings (PO)
• Lang subframe reinforcement (PO)

Misc. trim

• OE A/B/C pillar trim (PO)
• OE center console cubbies (PO)
• Euro center console (PO)
• Euro coin tray (PO)
• Euro side view mirrors (PO)
• OE CSL e-brake boot and handle (PO)
• OE AUX retrofit, center cubby (PO)

Modifications

• Eibach Pro Street S Coilovers (PO)
• Eibach front sway bar (PO)
• Bimmerworld sway bar end links
• CPI headers, ceramic coated
• N54 exhaust studs
• Dinan muffler
• HTE tune
• OE CSL rear diffuser (PO)
• Squared rear Style-67s, 265/35 square

Plans

• Headlight lenses & gaskets (✔️)
• Quarter window moldings
• Front bumper shave & respray (✔️)
• Strengthened front bumper mounts (✔️)
• Paint correction & ceramic coating (✔️)
• Touch-up rock chips (dr.colorchip) (✔️)
• Pole Position / SPG driver’s seat
• PCI seat base kit (✔️)
• Refinish steering wheel trim
• ZHP shift knob (✔️)
• Remove tint (✔️)
• Get stereo working properly (✔️)
• Bimmerworld front end links (✔️)
• Bimmerworld street rear camber arms
• Bimmerworld spherical RTABs
• Lemforder OE RTABs (4) (✔️)
• AKG 95A diff bushings, OE hardware
• Lower car (✔️)
• Alignment (✔️)
• Dyno tune adjustments (✔️)

While I'm the 6th owner, this car has never not been owned by an "enthusiast". Records dating back to the delivery of the car at the BMW Performance Driving Center in 2006, the original window sticker, and 100s of pages of receipts/maintenance records. The gentleman I purchased the car from works in the automotive industry (Porsche), the gentleman he purchased the car from works in the automotive industry (Rivian), I work in the automotive industry (Singer), so on. The car does have some kinks I need to iron out. CEL for a timing-related issue. The car intermittently won't start (either need to jump the car or just continuously try to start it 3/4 times for it to turn over). Only the right side of the speakers are working--the car does have an aftermarket amp and stereo system I would like to remove and go from there. I would like to start working on the car myself but need a garage and tools first.

Pictures:

First big stop at a buddy's house in the Bay Area after purchasing the car.







The drive home. Took the scenic route down via. CA-1/PCH through Monterey & Big Sur. One of my favorite roads in the US.







OG window sticker!



Finally made it back. How the car sits currently.





Lots of plans in store for the car! Will try my best to stay ontop of updates.

[Tbonem3]

Great find!

[WestBankM4]

I saw this car on CL, glad it found a good home. Great pickup, hope you source a garage and have a fun time wrenching on her.

[cornerbalanced]

I saw this car on CL, glad it found a good home. Great pickup, hope you source a garage and have a fun time wrenching on her.

Much appreciated!!

[robgill]

Beautiful car! Interlagos Blue is my second favorite color 😉.

[cornerbalanced]

Entry 1 - 10/29/22

Was able to get the car over to my mechanic earlier this morning to swap out the camshaft position sensors. Was hoping doing so would clear my check engine light and get rid of the timing issues I've been experiencing at idle. While the camshaft positions were original, and replacing them did result in the check engine light going away, I still have the timing issue at idle. If I allow the car to idle for long enough, a code or two will pop up like usual, check engine light will come back on, etc.





Fun picture to close out my first entry.

[Sharocks]

Damn man Porsche South Bay looking wild lol

[cornerbalanced]

Damn man Porsche South Bay looking wild lol

Hah, BBi Autosport

Porsche South Bay wishes!

[cornerbalanced]

Entry 2 - 12/5/22

Parts are slowing coming in for my VANOS teardown.

NOS S54 VANOS Unit sourced from Germany.





Beisan hub, upper chain guide, rattle repair kit, viton seals. Lang Racing cam bolts. Hack Engineering VANOS feed line.



Still waiting for my FCP order. VANOS gasket, valve cover gasket, misc. grommets, crush washers, regulating valve, timing chain guide rail, etc. etc. Fresh spark plugs and coil packs will also be thrown in.

[Casa de Mesa]

Congrats on the car!! Can't wait to follow along the work! Smart move doing VANOS right away.

[maupineda]

Would you mind sharing where and cost of the Vanos unit?

[cornerbalanced]

Would you mind sharing where and cost of the Vanos unit?

I was able to grab the unit for ~$1,100 shipped to the US. Retail is $3,000+ I believe? Not sure how many units (if any) are left at this point, I think bigger companies/distributors have purchased the majority of inventory at this point. Feel free to PM me if you’d like the sellers info.

[0-60motorsports]

Entry 2 - 12/5/22

Parts are slowing coming in for my VANOS teardown.

NOS S54 VANOS Unit sourced from Germany.





Beisan hub, upper chain guide, rattle repair kit, viton seals. Lang Racing cam bolts. Hack Engineering VANOS feed line.



Still waiting for my FCP order. VANOS gasket, valve cover gasket, misc. grommets, crush washers, regulating valve, timing chain guide rail, etc. etc. Fresh spark plugs and coil packs will also be thrown in.

Very Nice but why waste money on a brand new vanos unit when you could have just used the biesan parts to overhaul your current one.

Looking forward to more updates.

[cornerbalanced]

Very Nice but why waste money on a brand new vanos unit when you could have just used the biesan parts to overhaul your current one.

Looking forward to more updates.

1 - The helical gears within the VANOS unit wear over time. These helical gears are not replaceable unless you replace the entire unit.

2 - A ‘rebuilt’ coil pack will never perform as well as a brand new coil pack that comes included with a new unit. Most retailers like Dr.VANOS will even tell you this: if you want the most performance out of your VANOS, purchase a new coil pack.

3 - Although valve body’s can be cleaned, in my opinion, theres no comparison between a valve body / pistons with 150k miles and a brand new unit.

I’m going way overkill, in that I purchased a brand new unit and I’m refreshing said new unit with Beisan parts. I intend to keep this car for a while, so the added cost really isn’t a factor to me over say refurbishing my already broken unit or purchasing a used unit to refurbish.

[0-60motorsports]

1 - The helical gears within the VANOS unit wear over time. These helical gears are not replaceable unless you replace the entire unit.

2 - A ‘rebuilt’ coil pack will never perform as well as a brand new coil pack that comes included with a new unit. Most retailers like Dr.VANOS will even tell you this: if you want the most performance out of your VANOS, purchase a new coil pack.

3 - Although valve body’s can be cleaned, in my opinion, theres no comparison between a valve body / pistons with 150k miles and a brand new unit.

I’m going way overkill, in that I purchased a brand new unit and I’m refreshing said new unit with Beisan parts. I intend to keep this car for a while, so the added cost really isn’t a factor to me over say refurbishing my already broken unit or purchasing a used unit to refurbish.

Copy all.