2002 LSB build/maintenance journal

[Mpower04]

Here we go... again. I unexpectedly purchased this car earlier this year in April. As some of you may have been following I bought a silver E46 M3 before this in need of "some" TLC and was planning to make that the way I wanted. Fast forward a bit and I get a text from the then owner of the LSB asking if I was still interested. He had this car listed on M3F (rip) when I initially inquired several months prior but he decided to keep it. Like any maniac, I had to have it so I told him it's mine. I have wanted an LSB since 2013 after seeing one here and there around town when I lived in College Station and thought it was the coolest thing. I've had several E46 M3s prior to this but I think I finally found "the one". Just days after we agreed on a deal a friend and I were on the road from Austin, TX to St. Louis, MO.

The car is an incredible spec;
-LSB with black manual non heated seats
-Slick top
-No nav
-Halogen lights
-SMG (I like it)
-148,xxx miles

I'm the third owner. The car came with almost all the delivery documents to include a VHS tape that's still shrink wrapped and all of the keys. The only modifications were RAC wheels and Eibach lowering springs so this was a plus for me as I like to start with a blank canvas and prefer untouched cars. My plan for this is to keep it OEM+. I eventually ended up selling my silver one back to the individuals I got it from and we worked out a deal for me to keep pretty much all the parts I hard literally just installed.

The first time I saw it in person.

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Untitled by jake ellegard, on Flickr

Finally home.

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[Mpower04]

The first bit of maintenance I did was;
-belts/pulleys/tensioners
-fan clutch/fan (sounded like a bus)
-engine air filter
-fuel pump

There was some tinted film on the headlights/taillights I also removed.

After this the coolant temp would creep with the AC on so I ordered another fan clutch from FCP as I likely received a faulty one. It was perfect before.

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Swapped the brand new fuel pump I put in the silver one to the LSB

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Shortly after that I did rod bearings;
-ACL bearings
-OEM bolts
-motor mounts
-spark plugs
-oil pan gasket
-Liqui Moly 10W60
-new oil pump bolts
-steering coupler
-oil level sensor

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Old stuff

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Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr


That brings it up to where I currently am. I'm in the middle of doing the RACP reinforcement along with the Vince bar so I will update once that is done. Overall everything was in very good shape with only a few minor spots needing to be addressed.

[Mpower04]

Finally finished getting the car back together enough to put some miles on it. I wasn't very good about taking pics but the summary of what I replaced is;

-subframe reinforcement plates(CMP plates iirc)
-Vince bar w/ front gussets
-TMS solid subframe bushings
-TMS street camber arms
-TMS monoball upper inner control arm bushings
-stock upper/lower outer ball joints
-stock front diff bushing
-E36 M3 stock rear diff bushings
-stock differential fluid
-Syncro Design RTABs
-Stoptech stainless rear brake lines
-ATE Typ 200 brake fluid
-stock rear brake pads/rotors/sensors
-BW rear shock mount reinforcements

-Nissens radiator
-Rein upper/lower radiator hoses
-upper/lower temperature sensors
-Geba water pump
-BMW water pump gasket
-BMW water pump pulley/bolts
-BMW expansion tank w/ cap
-ECS overflow line
-Borg Warner thermostat
-block drain
-BMW coolant/distilled water

-BMW LED tail lights (previously eagle eye reps)
-BMW kidney grilles
-BMW side grilles
-L/R side turn indicators

-Gruppe M replica muffler. I typically do not use any replica parts but this was local and weighs 13 pounds so I'm giving it a shot. At some point it will probably be replaced but it beats the stock muffler.

I am currently running with no mechanical fan but I will be putting in an electric setup.

I used weld through primer, POR-15, BMW seam sealer and EZ coat in a stockish color over all my welds on the bottom/top side of the car. It looks pretty messy because I just used my finger to spread the seam sealer. I still have to paint the top side in the car.

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Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Just decided to scrape all this off.

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This all needs to be finished up but is good enough for now. Similar to the bottom I used weld through primer, POR 15, seam sealer and cavity wax where applicable.

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Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Some nasty brake fluid and radiator.

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Untitled by jake ellegard, on Flickr

Back under it's own weight.

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[0-60motorsports]

Awesome update. Why didn’t you go for the cmp subframe bushings to use with the plates

[Mpower04]

Awesome update. Why didn’t you go for the cmp subframe bushings to use with the plates

Thanks! I got a good deal on the plates from a local shop and already had the TMS bushings pressed in.

[jdauria]

Nicely done, this LSB is in better hands!

[Tbonem3]

Doing the Lord's work

[Mpower04]

Had a chance to get some things done recently and am due for an update.

George Hill and I worked out a deal for an E46 I had that involved some labor so he took care of bullet proofing the VANOS for me as well as a valve adjustment. I knew I was in good hands and he even took some pictures along the way. There was no broken bolts, no broken tabs and the chain guide was even intact.

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Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Reached the one year mark on the oil with only about 2k miles driven (so sad) so I changed it.

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Untitled by jake ellegard, on Flickr

+5hp

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I also got some Ground Control coilovers that recently went on. I have the fronts set to pretty much full low and there's still nearly a 2 finger gap in the front. Hopefully they settle in enough to be acceptable.

Pre assembled from GC.

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Untitled by jake ellegard, on Flickr

Had 265/285 Hankook RS4s put on at the same time.

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I know the badge is crooked, I didn't do it, and will be taking it off soon.

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I have Lemforder front control arms, control arm bushings and tie rods to go on next then I'll get it aligned.

[frenzy757]

Good work!

[Mpower04]

After getting the Ground Controls on with the 7" spring up front I wasn't happy with the ride height so they sent me out some 6" springs that I was able to get to an acceptable ride height without going full stance nation. Beyond that, I got it aligned and have been messing with the dampening. If I remember correctly I'm about 3/4 turn from full soft F/R and it feels pretty good. Any firmer and it's a noticeable difference in ride quality over the stock set up.

In other news, I picked up another project. I've been wanting a 4.6is for some time now but have never really been interested in paying what people have them listed for. Long story short one popped up locally that was super clean other than a nasty oil leak. We ended up getting a deal done and now I have it. I originally tried to buy it earlier this year from the individual who had owned it the past 12 years but I was beat to the shot. Since then it was passed around between a couple people who I assume didn't want to deal with the leak and eventually landed with me. Looking it over the day after I found the timing chain tensioner crush washer was missing all together causing the horrible leak. 99 cents later we were good to go with no more puking oil. The guy who had it the past 12 years did the timing chains/guides late 2016/early 2017 and this is where I'm assuming this was never replaced as carfax shows only about 3k miles driven between then and present day. After a visual inspection the chain also does look quite new compared to what else can be seen through the valve cover at 191k miles. Cold starts are also good. It also appears all the front arms/tie rods have been recently replaced and drives quite nicely after the alignment.

Since then I've been catching up on some deferred maintenance. So far;
-oil change
-window regulators
-engine air filter
-cabin air filter
-fuel pump
-hood struts
-alignment

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

The fix for why it was (primarily) passed around;

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Untitled by jake ellegard, on Flickr

Broken down on the toll road after the fuel pump failed while driving

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Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Also had a valve stem go out on the M3

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Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

The "fix" by someone previously. So far far I've got two new BMW regulators/clips for the front windows and will have to do the rear windows next.

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Untitled by jake ellegard, on Flickr

Broken one;

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New one installed;

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Well aged filters and hood struts were also replaced;

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Still a ways to go but off to a good to start and I'm glad I was able to save it.

[0-60motorsports]

Nice update! You will love the X5 after all the issues are resolved.

[Will]

Great thread. Thanks for taking us along.

[Mpower04]

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Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

[Loopyspec]

Love the progress

[Mpower04]

It has been a while! I haven't been very good at keeping track of everything so this will be more of a spam post. I ended up getting another project to get work on in addition to the rest of them as well.

-2004 ZHP Imola/alcantara with 147k
-6 speed (swapped)
-JB racing light weight flywheel
-Bilstein coilovers/Vorshlag camber plates
-Performance Gearing 3.46 3 clutch LSD with finned cover
-UUC swaybars
-RE transmission mounts
-ECS aluminum water/power steering pulleys
-BW dual fuel pumps
-Turner rear camber arms
-Style 216 wheels (no ZHP wheels)
-Brass caliper guide bushings
-stainless brake lines
-wheel studs
-swapped to silver cube from black
-GAS DISA upgrade
-AFE intake

I'm probably missing some things but that's most of it. It also came with a set of D Force LTW 18x9 wheels and a bunch spare parts. The PO had owned it for the last 5 years and done about 3 track events with it.

Now onto the problems. The PO was selling it because it had become more of a project than he wanted to deal with. It had a gas leak, a couple oil leaks, made a horrendous noise while steering with an equally horrendous steering feel, clear coat is peeling in a couple areas, good amount of dings (most should be able to be PDR'd), interior needs some love etc I enjoy bringing back cars like this so it was perfect for me.

After bringing it home;

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

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Low coolant light was on the following day. The bleed screw was broken so I took one off a new hose I had laying around. The whole system will be getting replaced soon.

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Cause for the fuel leak was the hose running between the dual pumps

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Steering noise/feel was due to a faulty steering rack. After tracking down a yellow tag rack I got it replaced along with new Lemforder tie rods, steering coupler and new boots. I didn't due a super thorough inspection before buying it and it ended up not even having a ZHP rack in it. It had a TRW rack. :facepalm I didn't take a tremendous amount of pictures during this as I was a bit pressed for time.

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Old rack

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I went after the windshield cowl next as it was duct taped to the windshield and falling apart. I also noticed the E box was missing all four screws so those were replaced as well.

by jake ellegard, on Flickr

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Loose wire is from a haphazardly wired manual swap

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Untitled by jake ellegard, on Flickr

Next I wanted to check the rest of the wiring. The pin running to the DME had came out of its connector. I will be going through and tidying everything up at a later date to include the reverse light wiring that can be seen in the previous pics. I'm on the lookout for a complete manual harness if anyone has one. While I was down there I noticed a leak coming through the brake booster so I'll be replacing the master cylinder and brake booster as well.

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

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Untitled by jake ellegard, on Flickr

Nice

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Started with jack pads as all of them were missing. One did not come with the insert so hopefully it doesn't fall out too soon.

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One of the pulleys was making some noise so I replaced the belts/pulleys/tensioners all at once along with the oil filter housing gasket, VANOS line etc.

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

EVAP monitor wasn't setting (no CEL) so I started with the easiest possible fix, the gas cap, replaced it and let it idle a few minutes then it set. Maybe that was the fix maybe it was a coincidence.

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

AC didn't blow cold when I bought it, PO said he would have to recharge every so often so I knew it was more than likely the evaporator. Did it over a weekend.

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Untitled by jake ellegard, on Flickr

Even if you're careful with the curtain airbag connectors they will likely get a little damaged removing them. They still clipped back in nicely and didn't come out with a tug I just used some electrical tape as an added layer of protection.

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Untitled by jake ellegard, on Flickr

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New evap with fresh foam

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Old evap

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Mostly back together. There's some things I want to replace before it putting it back 100%.

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Untitled by jake ellegard, on Flickr

Onto some random pics;

Traded my wife's Tiguan for her new daily. It was remarkably clean and very well optioned with a full service history so I had no choice.

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Had the wagon loaded down with bricks

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