2002 Steel Grey 6spd coupe Daily/Restoration project

[Tbonem3]

Some more maintenance. I think I mentioned it earlier, but while doing headers/CPV, I notice the Exhaust cam sensor was leaking. I decided to just replace both sensors (intake/exh).

Here's the leak (only exh side)



New OES(upplier) part from FCPeuro. Newer one is now gray and larger. Make sure to buy the o-ring! The intake comes with new o-ring, but not exh!




You can see the BMW logo ground off, it's a genuine part for half cost. Another pic of new sensors:



Exhaust is easy to change, just need a 5mm hex bit/key. Intake, however, is a PITA. Not only do you have to remove the manifold, but technically, you're supposed to remove the air and even fuel rail as the plug and wire for the sensor is hiding behind. I took a short cut that I'll explain.



There's a little plastic "cage" that you have to get out of the way



Now, you can get your 5mm hex bit back there, a wobble helps.



Since it's easy to do (2 x 10mm bolts), I removed the air rail for more access



Here, you can see the sensor's harness snug as a bug behind the fuel rail. So instead of removing the fuel rail and dealing with all those bitch clips, I just cut the harness so I could pull it out. Then, after installing new intake sensor, I plugged the harness in, and just stuffed the extra wire behind the fuel rail.




Also, even though I did a quick cleanout of the ICV, since the airbox was off, I wanted to do a better job. I got some new hose clamps as the oetikers are one-time-use, and I pulled the hoses of and cleaned everything thoroughly.

[Tbonem3]

Ok, last bit of wet sanding, I promise...

All that remained was the very top pillar "rail" of the passenger QP (respray)

Not the worst finish, but pretty rough where it meets the trim, as I assume the shop did not remove trim for the paint job. Example:



I took it pretty easy, just using 2500 grit, putting some more pressure where the trim is as that did need the most flattening.




Alright, all done sanding. I took it easy on the edge near glass as it's a sharp angle. I really wasn't looking to take the OP down too much here, just trying to match it to factory as much as possible since this is the last of the respray.



Time to buff



Had to do some by hand, right where the trim is




All done!




Still a little sloppy closer to the trim, but I didn't want to burn through the clear, so this is the best I could do.

Almost exact orange peel as factory, comparing to other panels:



This area was pretty rough, but now basically factory looking



Happy to be done, though it is kind of fun



Very proud of the restoration I've done to the exterior of this car. Pictured below is a recent pic, so no more body work. Hard, almost impossible, to tell it's not original (only hood/fender are factory):

[Tbonem3]

Figure now's a fine time to share some recent pics. I didn't feel the car was quite there yet until recently. It's still just a stock looking car with rashed 18s.

[Casa de Mesa]

You should be proud of the work done to bring this car to the state it is now. Looks fantastic, Tbone. Exceptional work.

[Tbonem3]

Thank you very much

[Tbonem3]

A couple of little things...

The front roundel is in surprising great shape, except for a spot at 7:30 that's badly worn. Can't cheap out now that the car is basically finished exterior-wise, so I ordered a new one.



Popped it off, and what do you know, more dirt.



Cleaned



New emblem and grommets



Fresh





One of the xenon plug boots is missing, which seems to be a common issue. I think it's usually this left one, I think it's looser. Anyway, I happened to find a replacement while browsing realOEM, but I had to figure out how to replace it!



I remembered another forum member saying that all our plugs can be disassembled (pin out?) so I fiddled with the plug and a small flat driver. Didn't take long, and I had it all apart:




et voila

[Casa de Mesa]

I always thought it was weird only one of those plugs for the xenon ballast had a boot. Thanks for posting the part number too.

[Will]

Car looks fantastic. Thanks for posting so many before / after photos, too!

[Tbonem3]

You're welcome guys, Merry Christmas!

Car looks fantastic.

Thanks!

[02_lsb]

I am 99% sure pre LCi cars only came with one boot. My car, and literally every other car I’ve seen only had one. I did the same as you and added the other.

[Tbonem3]

Weird

[lvm3sm46]

Speechless on the resto work. Your hard work can definitely be seen. Has your wife's uncle seen the car recently?

[Tbonem3]

Thank you! Ya he just keeps quiet lol

[Tbonem3]

Time to address the sagging/dented bumper and throw on my scorza muffler!

Boat anchor down - also take note of the dent or warping of the bumper up top



I've never removed a rear cover before, never had to. Surprisingly easy. A few screws/rivets at the back fender liner and a couple of "screws" in the trunk under the tail lights.



And it slides off.



It looks like the plastic just collapsed here. I'm not sure why, but I will try to shim it (the kevlar carrier slides right under so I can shim in between kevlar and the plastic.



Bumper back on, Slipped some dense rubber sheet in between kevlar and bumper cover - it evened out well! & Scorza on!



Love this muffler. Rarely see any posts about them or being for sale at all anymore. I had the SGT version on for a bit (on my other car), but it didn't quite sound as good. Not quite as loud or throaty. Less of that wail this thing makes. I'm really looking forward to how it sounds on this car with Fabspeeds' 55mm outlets. I always thought it sounded better with my 55mm euro headers or my friend's 55mm SSv2s than it did on my 63.5mm v1s.



Diffuser back on, everything done now.



A little video I took while my friend was driving it. so fuckin' güt:

Little thing: I noticed coolant was coming out the little expansion line. The o-ring was a new OEM Rein part, but we know those aren't the best. I didn't expect it to leak this bad so quickly. WOLFN8TR to the rescue with a new one



Luckily, the neck of the line wasn't damaged - it was all the coolant crusted up. Drained some coolant.



Getting the o-ring out is easy enough with a pick, but putting the new one is was a bear actually. I had to remove entire hose end to catch the new o-ring if I inserted it too far.

[lvm3sm46]

Sounds really good that Scorza