E46 M3 Project

[mwstewart]

Parts Update
A few more parts arrived at BMW. I've replaced the captive fittings in the dashboard that secure the belt-line trim, to make sure everything is nice and secure.


Also the pins that attach to the trim and in turn push into the captive fittings.


Some more of the Silver Cube arrived too.


I also replaced one of the sun visor clips that I marked when removing to fit the Bluetooth microphone.


I'm replacing all of the suspension nuts, too. The old ones had corroded.


CSL rear anti roll bar and bushes.


AV/ Aux in Complete
I bought a new trim surround for the Bluetooth Eject Box in the centre console, as the one I'd bought second hand had a few marks.


My Dad spent a lot of time helping me yesterday evening by making a template to mount my AV connections in the storage tray at the back of the Eject Box. We then made a prototype of the old housing and it worked out OK; here's the final result in the new housing.


I put some Silent Coat Absorber 15 underneath the Eject Box to cushion the AV wires.


The final result that I'm very happy with. The armrest hides this area when down, and the rubber mat that originally sat in the tray can turned upside down and placed over the connections to hide them.

The phono connections are for audio and video in via the TV tuner. The USB socket is a 12v to 5v adapter for charging USB devices, and the small jack is a direct AV in to the Nav system, which offers a slightly shorter signal route than audio in via the TV tuner.

Edited by mwstewart on Monday 23 December 21:33

[mwstewart]

Thanks everyone for the comments.

I won't ever sell the M3 or Fiesta; now I have the unit I can start to indulge myself with a collection

The HK Subs were replaced with Dayton Audio 'Classic' subs, and mounted in custom adaptors.

The next update will be in anything up to a month due to a substantial amount of my last parts order being on back order at BMW.

[mwstewart]

Small update.

I didn't show this last time, but here's the back of the Eject Box showing the fly leads I soldered on to the AV sockets.


In the end I decided to replace all of the Silver Cube trim trim, so that arrived and is now all fitted. The new trim has a real lustre to it that the cleaned second-hand trim had lost.


Folding mirror switch, installed and tested OK.


New CSL rear suspension components arrived. The dampers, springs, bump stops and some other mounting hardware are all CSL specific.


Here's a comparison of the original M3 rear springs (left) and the CSL versions (right).


Here are my new brakes:



The calipers are at an engineers at the moment for some machining. I'm going to rebuild the front caliper as it's suffered seal degradation as so many 996 GT3 fronts do. More on these in a later update.

Production of the GSR carbon airbox will be complete on July 15th, so I will book the car in at Evolve this week for fitting of the airbox and CSL exhaust, then an Alpha-N remap. This way I'll get a comparison of standard spec vs CSL conversion.

I also have a CSL boot lid on order (confirmed) and I've tracked down a roof too. I'm going to order a 'climate comfort' front screen too from BMW as the screen will have to come out when the bodyshop fit the carbon roof.

Edited by mwstewart on Monday 23 December 21:35

Edited by mwstewart on Monday 23 December 22:12

[mwstewart]

M159V8 said:

This just gets better and better

darreni said:

If the roof is coming via BMW, double check its a carbon one as they are NLA, & BMW are now supplying a steel skin as a replacement.

Thank you for the heads up. I actually fell foul of this already but thankfully the supplier refunded me; the part is still listed as 'carbon roof' and when it arrived, it obviously isn't. I had to source unsold dealer stock in the end.

HairyChineseKid said:

Hi,

Excellent project!, car is identical to mine, Titan Silver E46 Manual Coupe, just wondered where you sourced your CSL dampers and springs?

Cheers

Nick

Thanks Nick. I'm ordering everything new from BMW or http://www.bmminiparts.com/

Cheers,
Mark

[mwstewart]

bulldong said:

Awesome!

Thanks!

ccfj1 said:

Awesome Mark, loving the attention to detail, what was the price on them rear speings mate (Pm if you like).

Just a small note, I'm pretty sure that the green back mic (ending in 319) is the old non-noise cancelling version mate, the grey backed one ending 762, (BMW p/n 84-31-6 938-762) is the most recent one and updated for noise cancelling, (I just bought one last week (£35 from dealer)).

Thanks John! The springs are 33532282632 and were ~£175 for the pair from bmwminiparts. I must be out of date with the microphone; how long has the grey version been released? Thanks a lot for the info I shall order the later one.

[mwstewart]

carreauchompeur said:

Are you keeping a running tally of the parts costs? Knowing what BMW charge for relatively benign items the cost of this lot must be bonkers by now!

The total cost will be somewhere around £18k once completed, which includes the car itself. The problem is it's such a nice example that it really warrants the new parts - It just doesn't seem right fitting used parts inside to a car that still smells new inside! I do plan to keep it for a good few years and limit use to dry summer months, so it's also nice to know everything is perfect.

As a comparison equivalent cars to mine are on the market at dealers around the ~£16k mark:
http://www.autotrader.co.uk/classified/advert/2013...
http://www.autotrader.co.uk/classified/advert/2013...

I will have done OK given the eventual spec of my car

[mwstewart]

carreauchompeur said:

Excellent Man Maths there although the value of having the very best example on the market will always command a premium. If nothing else it's a great project...

Cheers

[mwstewart]

John, Thanks for the Mic info. The CSL is quite a bit lower than the standard M3. There are a number of suspension differences as darreni mentions, so it's quite probably best to keep the parts matched.

My car is a lot lower now than it was before - I'll post a comparison photo once the rear lower arms arrive and I've had a CSL spec geo.

[mwstewart]

I have purchased all new hardware to fit the rear ARB. For anyone else swapping the rear bar I found it was necessary to drop the exhaust back box on the N/S to provide clearance for fitting or removal of the bar.


In order to gain access to the upper mounting bolts for the ARB I found it was also necessary to remove a plastic guard/airflow management trim piece surrounding the charcoal canister. The fittings used on my car to secure the trim piece were mostly metal and given some had began to corrode, I chose to replace all of them. Where possible I swapped metal fixings with nylon as they are just as secure but obviously don't corrode.


I've read that the E46 can suffer from cracking around the turret mounting points so to mitigate this risk I ordered a set of reinforcement plates from a Z3, which also fit the E46. The reinforcement plates and CSL specific rear damper hardware can be seen in the photo below.


Here are the Z3 reinforcement plates in situ.


The CSL rear springs lowered my car too much, presumably because I have a full complement of options and no lightweight boot lid or rear glass. I ordered a set of 10mm rear spring pads and fitted them to compensate; the original pads are 5mm.


As the boot carpets were removed to fit the dampers I took the opportunity to pressure wash them.


Here is the car just after it was lowered off of axle stands.


I took the car for a decent drive last night and I am over the moon with the suspension. The ride is firmer but is by no means harsh, and where the car was previously neutral and could feel slightly ungainly over fast transitions, it's now more rear-biased, sharper and much more controlled. The new suspension has highlighted the low rack ratio so this is something I do need to address but for now I'm very happy.

The CSL rear camber arms are still on order but once they arrive they will be fitted and adjusted to CSL spec. I also need more power and I'm thinking about how to achieve that without ruining the entire ethos of the model.

Edited by mwstewart on Monday 23 December 21:36

Edited by mwstewart on Monday 23 December 21:40

[mwstewart]

aspirated said:

That really does look like the perfect height, great update as usual!

Thank you. I'm also very pleased with the height.

darreni said:

I think the camber arms are NLA IIRC.

Thanks Darren. You prompted me to check my order with the supplier! The arms are confirmed as due in Germany on the 23rd of July. I'm told that issues arise when the order is placed and not after payment is made, so I hope everything works out OK.

martin mrt said:

Mark, I followed your fiesta thread with great interest, not that I was interested in Fiestas, more the standard of modifications, and how well executed they are.

Not forgetting the detailed and informative write ups.

This thread is even better, your doing exactly the type of modifications I would on a car that I am very interested in.

Keep the updates coming.

Thanks Martin. I see you've had an E46 M3 and speak highly of it, though I appreciate the E92 is a better day-to-day prospect. The only thing that doesn't quite hit the spot for me with the E46 is the power output - it's the only area that I'm not happy with at the moment.

[mwstewart]

bulldong said:

Stunning car.

Cheers

Max_Torque said:

Now it could be just the way the car is sitting on the gravel, or the angle of the pic, but it looks too low at the back to me? M3's have always had just the right amount of nose down "rake" to make them a) handle well and b) look purposeful!

Ahh, yes, the top of the rear arch is lower than the front so mine still has the correct attitude despite looking otherwise.

Examples:

[mwstewart]

martin mrt said:

It's a pleasure. I certainly did, I went down a very focused route with the E46 (intrax coil overs, super sprint exhaust, genuine CSLs and APs) I never fitted the APs, but as an everyday road car I ruined it, perfect for A/B road runs but as an everyday car It was awful. Returned it to standard before I traded it in, and questioned why I messed with it. I was a fool that thought he knew better than the clever chaps at ///M

It was my first "fast" and RWD car, I understand what you mean, I did sometimes find mine lacking a little, however once you fit that air box and get it mapped with the Alpha N I'm sure you will have no cause for further complaints.

E90/92, the 90 in my case as I need rear doors is a perfect car for me at the moment, bar the OEM exhaust mod, I have yet to touch any of it, the only things I've considered adding are the electric rear sunshade and the TV tuner.

Keep the updates coming, I look forward to them

Thanks Martin, if I ever get tempted to fit coilovers I'll remember your post Ironically the AP's would have improved the car. My pad warning light has just come on for the original discs and pads, so I need to get the new brakes on ASAP.

ManOpener said:

Too low? I'm not aware of any way of significantly increasing the power output (more than 400bhp) of the S54B32 without fundamentally changing the nature of the engine (forced induction) or spending a great deal of money (various 3.4/3.5 litre stroker kits). Have you got any plans in this regard?

Yes, too low. I wouldn't want to stroke a high-revving N/A motor but I understand some have and make 420 on the 3.4 spec crank and pistons. I know FI gets good gains but I don't like it (in this car) for the reason you stated.

I'm currently investigating a set of Schrick cams to complement the CSL Airbox and Exhaust system - the Airbox in particular apparently benefits from a longer duration inlet cam. Given the standard M3 repeatedly makes below the stated output, usually 335bhp, I'd like to end up with a genuine 370bhp. I'll see an additional 35bhp is enough to make me happy.

[mwstewart]

I accidentally deleted all previous M3 images from my server, so if you're reading this thread for the first time anything other than this post won't make a lot of sense I will upload the old images again soon.

My airbox has been produced and I have ordered and collected the CSL specific hoses and clamps ready to fit.


E86 Z4M Steering Rack
The CSL suspension continues to impress me and in fact I'm actually shocked how much it has improved the balance of the car. Body control is increased tremendously but there is sufficient movement which makes it that bit easier to know when it will break traction. It's perfect road suspension. The suspension does have a downside and that is its ability to highlight what is in my opinion a silly steering rack ratio. It's just way too low. I knew from its ratio that the CSL rack wouldn't be a whole lot better so I've gone for a Z4M Coupe version.

Ratios of the rack in the E46 family are as follows:
E46 M3: 15.4.1
M3 CSL: 14.5.1
Z4M Roadster: 13.7:1
Z4M Coupe: 12.8:1

I was lucky enough to find someone breaking a Z4MC with the same mileage as my car (27k). Here are the two racks: the original M3 rack is at the top and the Z4MV rack at the bottom.


Original M3 rack:


Z4MC rack. Note that this is an original rack therefore has a part number ending in 0.All racks supplied by BMW after the model ceased production are re-manufactured and will have a higher trailing digit; 5 is the current value.


The M3 has a rubber steering Giubo in the UJ linkage that's purpose is to absorb kickback through the wheel, which it does well, however it is at the expense of steering feel. I had read elsewhere on the internet that the solid Z4M coupler is a straight swap, but like a lot of things I read on on the internet, it was incorrect! The spline locating flats on the Z4 part are in completely different orientation to that on the M3.

In the end I have settled on http://www.akgmotorsport.com/catalog/catalog.php?c...

Note: There is a crash safety aspect to removing the Giubo so please ensure you understand the implications if you choose to do the same.

Z4M top, M3 bottom.


Whilst I was under the car fitting the rack I noticed a few bolts had begun to corrode, so to make future maintenance easier I have replaced whatever I came across that wasn't perfect.


I used new BMW bolts and fluid to fit the rack, and had the car tracked (full alignment to follow when the CSL rear arms arrive) and the steering angle sensor recalibrated.


The rack has made a pleasant difference, and whilst not as dramatic as the suspension change, it has served to improve the driving experience. All the changes I'm making are really beginning to add up.

As the car was being tracked I had the CDV removed at the same time, and this has reallylivened up clutch pedal response. There is no longer a lag when changing gear.

I had a full CSL exhaust for the car but have now decided to get Supersprint manifolds, cats, and mid section, so the CSL system is now for sale: http://www.ebay.co.uk/sch/mw_stewart/m.html?_nkw=&...

[mwstewart]

Gingernuts said:

Hi, good effort on the build, some great attention to detail.

One question.

Would it not have been more beneficial to go with a high quality coil over to give you adjustment as apposed to standard csl stuff. I have a CSL and have gone for KW V3's which are still progressively wound springs and are still compliant on the road, but give me adjustment for the track too.

Thank you. I'm building this as a fast road car so the coilovers would have been that little bit too harsh, even on the low setting, and I doubt I'd get the benefit of them on the road. My car won't see a track as in honesty I think it's too lardy to be a really decent track car.

I know the KWs are fantastic kit(I have V3s on my Fiesta project) and I'm sure they are great for your CSL.

[mwstewart]

Gingernuts said:

Fair enough. Makes sense. My kws will go softer than standard if required. Much better than standard even for fast road. Allowed a geometry change that made it turn in a lot nicer.

Thanks, that's interesting. Is the geometry change you speak of the additional one degree of camber at the front? I know this chassis responds well to that but I understand it can lead to a lot more tramlining on the road. What did you do and what do you think to the on road manners? If it is the additional camber, I take it that can't be achieved by removing the standard locking pin on the OEM top mounts?

Cheers.

[mwstewart]

Glenred said:

My M3 came with KW's fitted, I want to take them back to standard OEM.

Never gonna track it and prefer the comfort and ride of the standard kit.

Been scanning eBay for a full set.

My entire suspension is for sale: http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&am...

[mwstewart]

Minor update. The car was taken out of hibernation to visit BMW main dealer Sytner (Nottingham) for a rear subframe check, where it was given a clean bill of health.

I will probably get the rear end reinforced at a later date to make sure it stays that way, but with the kind of mileage it covers it'll probably last me a lifetime anyway.

[mwstewart]

Some of the CSL parts I ordered earlier on this year are starting to trickle through.

CSL rear camber arms.


A CSL boot lid.


..but I'd already bought a genuine lid that was new last year and sprayed in Titanium Silver. There's another on order with BMMiniparts too - all because I couldn't be sure of when one would turn up! They will sell easily enough. I've also tracked down a new CSL front bumper and roof in Germany.


OEM E46 reverse camera kit. The kit comes with a mounting plate that incorporates the boot release button, which is something usually lost when fitting a CSL lid.


Battery cover trim; mine has a small crack.


New tie rods and track rod ends, and front ARB links. The rest of the suspension is brand new so I wanted to keep everything in sync. I'll get the RTAB's done, CSL arms fitted, and a CSL geo to finish.


Next mods will be a 3.91:1 rear Crownwheel and Pinion, a complete Supersprint Exhaust, and an Evolve Alpha-N map with the GSR Airbox.

[mwstewart]

Thanks chaps. I don't ever plan to sell it

The reversing camera kit is part number 66210447960.

[mwstewart]

dom9 said:

I think p4cks said that, before some vulture swooped in

Haha. The only way this will go is if my next car makes the M3 feel completely obsolete, but I have a feeling the E46 is always going to be an interesting car to have in a collection.

_Batty_ said:

Usual stunning attention to detail.
My 330ci has a Dynavin head unit which looks OEM, but is rather infuriating to use even though it has Bluetooth, nav etc.
I think I'd have preferred the old widescreen nav unit and use a parrot system or something similar.
What's next on the list?

Cheers! I had read some bad things about the Dynavin and other similar units, but I should imagine they are still better than the Business CD or tape The OEM Nav can be had for a reasonable amount now and it still works well enough.

Next on the list is brakes, followed by some more tuning.