E46 BMW Social Directory E46 FAQ 3-Series Discussion Forums BMW Photo Gallery BMW 3-Series Technical Information E46 Fanatics - The Ultimate BMW Resource BMW Vendors General E46 Forum The Tire Rack's Tire Wheel Forum Forced Induction Forum The Off-Topic The E46 BMW Showroom For Sale, For Trade or Wanting to Buy

Welcome to the E46Fanatics forums. E46Fanatics is the premiere website for BMW 3 series owners around the world with interactive forums, a geographical enthusiast directory, photo galleries, and technical information for BMW enthusiasts.

You are currently viewing our boards as a guest which gives you limited access to view most discussions and access our other features. By joining our free community you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is fast, simple and absolutely free so please, join our community today!

If you have any problems with the registration process or your account login, please contact contact us.

Go Back   E46Fanatics > E46 BMW > E46 Touring

E46 Touring
The E46 touring forum. Talk about your sport wagon E46 here.

Reply
 
Thread Tools Search this Thread Rating: Thread Rating: 6 votes, 5.00 average. Display Modes
Old 02-29-2016, 12:22 PM   #1
kaiv
Registered User
 
Join Date: Oct 2007
Location: San Diego, CA
Posts: 601
My Ride: E46 325iT S54
My M325iT project

Excited to see some fellow Touring enthusiasts here so although I'm mostly on M3forum, I figured I'd share a cliffnotes version of my current project here :-)

Started with a one owner automatic 325 with the following specs:

2004
Japan Red
Grey Interior
5AT
ZPP - Premium Package
(Wood trim, Power seats, Auto dimming rear view mirror, Rain-sensing wipers, Moonroof)
ZSP - Sport Package
(3-spoke steering wheel, Sport seats, 17 sport wheels, Sport suspension)
HID headlights
Heated front seats
HK Premium sound
Rear PDC





Then picked up a salvaged donor.







Which used to look like this (drove awful!).







Began parting it out, starting with the interior.







Running out of space lol.





Finished taking the car down to the bare frame at a good friend's shop.

















Timelapse video.



Got rid of chassis and brought parts home.



kaiv is offline   Reply With Quote
Ads by Google

Guests, get your FREE E46Fanatics.com membership to remove this ad.
Old 02-29-2016, 12:23 PM   #2
kaiv
Registered User
 
Join Date: Oct 2007
Location: San Diego, CA
Posts: 601
My Ride: E46 325iT S54
Went on to prep the motor for install:

WPC treated rod bearings (M3dragon GB)-



Had forgotten how nice it is to work on an engine that's not in a car!



Opening it up. Found a piece of chain guide and sealant on the drain plug but no washer.

Upon closer look the drain plug has been time serted. Hope it'll seal properly with a new plug and new washer.



Yup.



Oil pan removed.

No damage to the oil pump's screen and it's clearly been doing its job!





Oil pump removed.



Looks good!!



Blue (#440) goes in the rod, red (#439) goes in the cap.





Plastigauged one because why not



Mother of all torque wrenches



Procedure for M10 bolts is 5NM application torque, 30NM joining torque, 105 angle torque. Release the bolts and repeat 3 times.

Edit for clarification: 3 times total tightening, so slacken the bolts and repeat 2 times (3 times total but no more than 5 times per TIS)



Looks good (desired clearance is 0.030 - 0.070mm)



Looks so nice when new



Redline assembly lube.



Everything looks great in there!!





Old shells.



Original bearings with 125k.
Pretty typical in my experience and consistent with other S54s I've done (which were all between 120-140k)



Oil pump back in, nut loctited and screen cleaned. Dirko grey sealant on the seams.



New gaskets and seals.






Beisan Vanos-

Sure enough, found the upper chain guide in two pieces



Vanos and cam gears removed

[IMG][/IMG]

Full rebuild/reseal with upgraded pump disc and rattle kit from Raj @ Beisan









Updated cam bolts





Vanos installed



Valve adjustment



Wrapped that up and did a little cleaning up



Threw on a high temp viton fluoroelastomer CPV o-ring from John (Mpower22)



And got the car all wired on paper.



Huge thanks to Terraphantm for pointing me in the right direction, taking the time to double check my notes, and catching some mistakes!

Meanwhile, my friends are going crazy and buying all the local Tourings




Last edited by kaiv; 02-29-2016 at 12:24 PM.
kaiv is offline   Reply With Quote
Old 02-29-2016, 12:23 PM   #3
kaiv
Registered User
 
Join Date: Oct 2007
Location: San Diego, CA
Posts: 601
My Ride: E46 325iT S54
With the motor ready and wiring mapped out, surgery began!

Brough engine hoist home (can't do that with a sedan/coupe/vert tehee)





Work space.



Hoist ready.
(The M3 is my roomate's. It's a spotless 05 garage queen with ~15k miles and tentatively for sale /plug).



The stage is set!



Mileage of Touring.



Mileage of donor at time of part out for reference.



Put the car up on all 4 to drain the fluids.



Then pulled the front clip.



Amazing the amount of crap wedged in there. The M3 had the same.







Removed a few more components, basically getting rid of everything in the way of the motor.





Removed the transmission.



Found out it's a GM trans that's made in France. What was BMW thinking :screwy::lolhit:







Finally, pulled the motor!



Goofy removal video (sped up 4x but sound is not for some reason)







I then decided to get some of the rear axle bits ready. All new OE Lemforder upper/lower balljoints and camber arms.





Had a blown ball joint.



Lemforder replacement.





Next I decided to turn my attention to the fuel system which was fully converted to M3.

Fuel pump, baffle, sending unit, sucking jet pump, lines regulator etc
New unit gaskets, fuel filter and o-ring.





Stock 325 fuel filter with integrated pressure regulator. Note the traditional hose clamps. The M3 setup has quick disconnect fittings throughout the pressure side. Much neater!





Non-M pick up.



M3 setup with baffle.





With that done I went to clean the engine bay.



New motor mounts.



Got rid of the wide automatic brake pedal and added clutch pedal.





Looking in the transmission tunnel. Shifter hole already present as well as the stationary rod mounting bracket. It was nice not to have to do those for once (smg m3s!)






Last edited by kaiv; 02-29-2016 at 12:27 PM.
kaiv is offline   Reply With Quote
Old 02-29-2016, 12:23 PM   #4
kaiv
Registered User
 
Join Date: Oct 2007
Location: San Diego, CA
Posts: 601
My Ride: E46 325iT S54
Original marshmallow trans mounts.



Annnnd placed the S54 in the bay :parrot:



Installation is reverse of removal

Engine view from trans tunnel.



New OE clutch, flywheel, pilot bearing, bolts.



Transmission prepped and ready to go in. New guide tube, clutch fork, throwout bearing, stainless steel pivot pin with clip, selector rod joint etc Redline high perf grease where applicable.



Transmission installed with shift linkage. New bushings everywhere. Went with the OE BMW performance shifter.





Back up front: M3 radiator, M3 powersteering cooler, M3 oil cooler and stock 325i air duct/cover fitted.







I test fitted the M3 one but it would have required some trimming and massaging. I decided to not do that and run the stock 325i unit for now. I will probably do a ZHP duct/bumper combo in the future for better air flow.

For reference; top = m3, bottom = 325i. The difference is massive.



Front clip back on!!





Next I went to work on the rear end.

Dropping the subframe.



This little Harbor Freight jack is amazing. I use it for front/rear subframes, transmissions, exhausts... Very versatile!







Cleaned up the mounting points to inspect for cracks. None found as expected (only has 184hp after all!)









M3 subframe. The subframe and diff mounts looked just fine so I decided to reuse them for now. I will probably do a weld-in reinforcement at some point in the future and will just swap them at that time.



M3 differential.



M3 upper and lower arms.



M3 trailing arms and axles.

Those were a bit challenging to install in one piece with only two hands, had to get a little creative lol.



Rear end mostly done! Reusing the 325i shocks and springs for now.







BTW 325i and M3 axles ended up being the same length as mentioned previously. See expert scientific measurement below



M3 rear brakes (will take care of the rattle canned calipers at a later time)



Driveshaft installed.



Exhaust installed.



Will have to figure some type of muffler to be adapted here.



Back in the engine bay to wrap up a few things.

Oil cooler lines (new o-rings)



New pullies, belts, powersteering lines.



Auxiliary waterpump and coolant hoses.



The covers on the left side of the engine compartment are virtually identical between both cars but the M3 one says M3 on it so that's the one I put


Last edited by kaiv; 02-29-2016 at 12:30 PM.
kaiv is offline   Reply With Quote
Old 02-29-2016, 12:28 PM   #5
kaiv
Registered User
 
Join Date: Oct 2007
Location: San Diego, CA
Posts: 601
My Ride: E46 325iT S54
Made a temporary hose for the fuel tank breather valve under the intake (wil get OE hose from dealer).




Refill time!!



Priming the oil filter.



Pressure testing the cooling system.



At this point I grabbed those two things which I had been saving for last :parrot:



And began wiring.



E-box.

Not a single original wire to the car was cut anywhere. All factory pins everywhere and clean taps where needed. Solder and 3M heat shrink tubing.



Clutch switch harness.





Example of wire tap (those were taken on another car)











Oh and this. I must have the Sport button even though I'll never use it :lolhit:



With the bulk of the wiring done, I reconnected the battery and turned on the ignition.... Fuel pump primed, cluster lit up, and throttles actuated!! I was ecstatic!

Intake manifold and air filter housing went back on. Fuel pressure was released and pump fuse removed. I re-triple-quadruple checked everything and gave the car a few cranks to build oil pressure.

Reconnected the fuel pump fuse and this happened:





This was only 4 days after driving home with the hoist in the trunk

Finished buttoning up a few things and it was back on the ground the next day for a first drive!







And the money shot!!



First drive:


Last edited by kaiv; 02-29-2016 at 12:34 PM.
kaiv is offline   Reply With Quote
Old 02-29-2016, 12:30 PM   #6
kaiv
Registered User
 
Join Date: Oct 2007
Location: San Diego, CA
Posts: 601
My Ride: E46 325iT S54
Got some top notch programming done by Terraphantm on a couple of my modules to restore proper vin/mileage along with some rear door ajar LEDs installed



Random snapshots:





And this is how the car stands as of today. I have 600+ miles on the conversion and it's a complete blast to drive! Still have a few more things I want to do though :-)

Last edited by kaiv; 02-29-2016 at 12:39 PM.
kaiv is offline   Reply With Quote
Old 02-29-2016, 01:42 PM   #7
Geo31
Ironman
 
Join Date: Mar 2003
Location: The Woodlands, TX, USA
Posts: 2,556
My Ride: 98 M-Z3, 01 325iT
Oh sweet!

Don't be a stranger around here.
__________________
George Roffe

Swim: 2.4 Miles
Bike: 112 Miles
Run: 26.2 Miles
Brag: For the rest of your life


Geo31 is offline   Reply With Quote
Old 02-29-2016, 09:12 PM   #8
dinanm3atl
Registered User
 
Join Date: May 2007
Location: USA
Posts: 150
My Ride: M3
Send a message via AIM to dinanm3atl
Wow. Awesome work and very quickly done.
dinanm3atl is offline   Reply With Quote
Old 03-01-2016, 05:16 AM   #9
MichaelStar
Registered User
 
Join Date: Oct 2015
Location: BG KY
Posts: 154
My Ride: 325 Touring
That is quality work!
MichaelStar is offline   Reply With Quote
Old 03-01-2016, 09:09 AM   #10
Solidjake
Zero. Leaks.
 
Solidjake's Avatar
 
Join Date: May 2008
Location: NYC
Posts: 29,130
My Ride: '02 330i 6MT
!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! I freaking love threads like these. INCREDIBLE WORK!!!!!
Solidjake is offline   Reply With Quote
Old 03-01-2016, 10:16 AM   #11
Jaundiced Outlook
Registered User
 
Join Date: Jun 2010
Location: Virginia Beach, Virginia
Posts: 467
My Ride: has a tailgate
Wow, what an amazing job!
__________________
2001 325iT 5-Speed
Jaundiced Outlook is offline   Reply With Quote
Old 03-01-2016, 01:29 PM   #12
YBimmer
Registered User
 
Join Date: Oct 2014
Location: Boston, MA
Posts: 75
My Ride: 03 330iZHP/02 325XiT
Amazing!!
YBimmer is offline   Reply With Quote
Old 03-01-2016, 02:37 PM   #13
jmb
Registered User
 
Join Date: Aug 2004
Location: chicago
Posts: 235
My Ride: an old wagon
It is an impressive build.
jmb is offline   Reply With Quote
Old 03-01-2016, 04:28 PM   #14
Notnrml1
Registered User
 
Join Date: Mar 2015
Location: NCCBMWCCA
Posts: 39
My Ride: E46 xiT manual
Speechless...4 days!
__________________
Understeer is when you hit the wall with the front of the car and oversteer is when you hit the wall with the rear of the car. Horsepower is how fast you hit the wall, and torque is how far you take the wall with you.
Notnrml1 is offline   Reply With Quote
Old 03-01-2016, 08:48 PM   #15
Busta Rib
Registered User
 
Join Date: Mar 2014
Location: Seattle
Posts: 24
My Ride: 2002 325iT
Awesome conversion and build. Doing an S54 conversion is something on my touring bucket list. Thank you for the inspiration and documentation. Nicely done.
__________________
2002 325iT TiAg/black 6-spd
Busta Rib is offline   Reply With Quote
Old 03-02-2016, 05:39 AM   #16
shellback
Registered User
 
Join Date: Jul 2009
Location: Jax, FL
Posts: 146
My Ride: BMW with rear wiper
When can I drop off mine
Awesome work Sir!
shellback is offline   Reply With Quote
Old 03-02-2016, 05:35 PM   #17
gerstnerstrasse
Registered User
 
Join Date: Jan 2016
Location: San francisco
Posts: 1
My Ride: Various BMWs
Great build! What year was the donor M3? Any considerations in making it smog legal in CA?
gerstnerstrasse is offline   Reply With Quote
Old 03-02-2016, 09:00 PM   #18
Merlin8
Registered User
 
Join Date: Dec 2015
Location: San Diego
Posts: 25
My Ride: 1991 318i
Mother of God.

This is why you have been slow to respond to IM
Merlin8 is offline   Reply With Quote
Old 03-03-2016, 10:56 AM   #19
Onizukachan
Registered User
 
Join Date: May 2015
Location: El Paso, TX
Posts: 344
My Ride: `04 M56 Touring
Quote:
Originally Posted by Busta Rib View Post
Awesome conversion and build. Doing an S54 conversion is something on my touring bucket list. Thank you for the inspiration and documentation. Nicely done.

Ditto. Well done.
Onizukachan is offline   Reply With Quote
Old 03-09-2016, 12:10 AM   #20
kaiv
Registered User
 
Join Date: Oct 2007
Location: San Diego, CA
Posts: 601
My Ride: E46 325iT S54
Thanks fellas, I'm glad you like it :-)

Yes it is full CA/smog legal. More on that soon.

Small update: I got to put it on scales and was pleasantly surprised:



This is full weight with a tick under a quarter tank of gas.



Out of curiosity I removed the cargo cover/partition net, the spare tire, tool kit, jack etc and that dropped a whopping 87lb (!)





kaiv is offline   Reply With Quote
Reply

Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes Rate This Thread
Rate This Thread:

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Censor is ON





All times are GMT -5. The time now is 02:02 PM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2016, vBulletin Solutions, Inc.
(c) 1999 - 2016 performanceIX Inc - privacy policy - terms of use