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Icon1 n54 engine swapped e46 wagon build thread - 07-03-2019, 09:11 AM

Hello everyone,

I have started to build a n54 swapped e46 wagon.
Please share, like comment, subscribe and check out my YouTube channel for weekly build update.

I'll try to post some of the progress on the thread as well.
Thank you in advance for all your support.



https://www.youtube.com/channel/UC7H...o9zfL4b8JaNiGQ




2001 325ti (e46 wagon)


2001 325ti (e46 wagon)


e46 engine is out



e46 interior is out


2009 bmw 335i, n54 donor car.


335i front end is removed.

Please share, like comment, subscribe and check out my YouTube channel for weekly build update.

https://www.youtube.com/channel/UC7H...o9zfL4b8JaNiGQ

Last edited by breakabolt; 07-22-2019 at 09:48 AM..
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Default 07-09-2019, 01:54 PM

Not sure what you're using for a camera, but it might behoove you to get an external microphone like this one:
https://smile.amazon.com/Microphone-...s%2C160&sr=8-8

Since you're filming outside, it would help cut down on ambient noise a bit.

I look forward to this project.
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Default 07-09-2019, 01:56 PM

Now would also be a great time to add an oil cooler to the N54, since it's missing the option.
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Default 07-09-2019, 11:39 PM

@mrmax1984
I'll probably look in to getting an external mic, tnx for the link. I'm planning on adding an oil cooler at some point, before the engine gets settled in to the E46 bay for good. Thank you for the support.
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Default 07-18-2019, 10:12 AM

N54 engine is in the E46 engine bay. I may have to do few custom modifications in the engine bay. just a few issues, nothing major.
check the link for the video.

https://youtu.be/Vs-SjjUZSls
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Default 07-22-2019, 09:53 AM

N54 engine is ready for a test fit


N54 in E46 engine bay. engine is sitting a bit too high. got to make some custom mounts or modify the sub frame.

E90 interior is coming out.


Front interior is out.


Please share, like comment, subscribe and check out my YouTube channel for weekly build update.

https://www.youtube.com/channel/UC7H...o9zfL4b8JaNiGQ
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Default 07-22-2019, 12:50 PM

very cool


Burger Motorsports
Home of the JB4 the worlds most popular turbocharged tuning system!

It is the sole responsibility of the purchaser and installer of any BMS part to employ the correct installation techniques required to ensure the proper operation of BMS parts, and BMS disclaims any and all liability for any part failure due to improper installation or use. It is the sole responsibility of the customer to verify that the use of their vehicle and items purchased comply with federal, state and local regulations. BMS claims no legal federal, state or local certification concerning pollution controlled motor vehicles or mandated emissions requirements. BMS products labeled for use only in competition racing vehicles may only be used on competition racing vehicles operated exclusively on a closed course in conjunction with a sanctioned racing event, in accordance with all federal and state laws, and may never be operated on public roads/highways. Please click here for more information on legal requirements related to use of BMS parts.
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Default 07-25-2019, 08:19 AM

check out the video on removing the e90 interior.

https://youtu.be/cfcY9lMqIwc
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Default 08-01-2019, 09:23 AM

Took the interior off of the E90. Got the wiring harness out and labeled, I got to thin out the harness by removing unwanted stuff and swapping it over to the E46 body. It is quite time incentive to take it apart and document. The harness and everything looks intimidating. The dream of swapping E90 interior into E46 may be a little far fetched. But, hey at least others don't have to guess if its possible or not. I'm still rooting to swap the front interior and try to make it look stock. fingers crossed.



check out the video on YT

https://youtu.be/SYOtGfaz1TU

Last edited by breakabolt; 08-01-2019 at 09:35 AM..
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Default 08-15-2019, 09:30 AM

Finally I was able to jump back on to the E46 and build instead of taking things off.
Started the first part of reinforcing the rear sub frame mounting points.



Check out the video on Youtube.

https://www.youtube.com/watch?v=4_qHWlsBXAk
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Default 09-12-2019, 10:08 AM

Got around to install the VinceBar rear reinforcement kit.
I hope the E46 wagon rear end is able to handle up to 1000whp with both
reinforcement plates and Vinces bar installed. I'm not planning to gain that much hp. my goal is to get 400hp and around same amount of torque.

check out the install video on youtube.
https://youtu.be/f-5Fvf_6XVw













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Default 09-13-2019, 12:13 PM

Nice looking forward to seeing this project completed.
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Default 10-01-2019, 10:32 AM

Quote:
Originally Posted by datbimmer
Nice looking forward to seeing this project completed.
Thank you for the support.
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Default 10-01-2019, 10:46 AM

Started working on a budget Big Brake Kit setup, its taking some time due to R&D.in the mean time replaced the CSB (center support bearing) on the m3 drive shaft

check out the video on Youtube.
https://youtu.be/AofgO3FQLMM


new csb bearing


make sure to mark a line on both sides of the driveshaft to make it easier to put it back together. the driveshaft is balanced from factory. It is important to keep the orientation as it is. Use a 18mm wrench and a prybar or a big flathead for leverage and remove the inner bolt.




use a pulley puller to remove the bearing.




Last edited by breakabolt; 10-01-2019 at 11:00 AM..
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Default 10-04-2019, 04:20 PM

Got around to concentrate on brakes. I was able to retrofit E90 335i front brakes and E46 M3 rears in to E46 wagon.
It looks easy but had to do quite a bit of R&D to get it going. hopefully it'll help others to do the retrofit and gives them a starting point.

You can check out the how-to retrofit 335i calipers on to E46
https://forum.e46fanatics.com/showthread.php?t=1263569

or check out the youtube video on

https://youtu.be/eiacEuYc56M

as always, subscribe, comment, like and share.


stock 325i vs 335i brake setup







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Default 05-27-2020, 01:33 PM

I was able to replace all the bushings on the rear end with poly bushings. Check out the video on YT.

https://www.youtube.com/watch?v=jRzIK3ULYTE


burning off the old sub frame bushings


removing the old bushing from rtab


garagistic complete e46 M3 bushing kit

https://www.garagistic.com/collectio...ll-bushing-kit




new rtab bushings


cleaned and painted sub frame.


sub frame bushings in.


diff bushings.
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Default 05-27-2020, 01:36 PM

Rebuilding E46 M3 rear brake calipers

https://www.youtube.com/watch?v=vsuczL_Q57Y


Using air pressure to remove the piston. FYI: it is under pressure, please keep your fingers away from the piston.


use a pick tool to remove the inner seal and replace the new seal. don't forget to lubricate them as well.


put the dust boot on the piston


push the piston in with all you might.


replace old guide pin boot.

https://i.ibb.co/PQQW44M/done.jpg
calipers are done with fresh seals.
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Default 05-27-2020, 01:36 PM

As I said before I got the m3 rear end from a donor car after an accident. What I didn't realize was that the outer CV joint was damaged on the driver side, until I took the whole assembly apart.
Furthermore, while taking apart the axel I found out the inner CV joint is crap as well. MY luck

As usual I found another used axel with torn cv joint boots for way less than it cost new. new axel is $600 I got mine for $100.

So, in good old fashion I decided to put both axels parts together and make one good working axel.

So this video should help any one planning to replace the inner cv joint or cv joint boot.

Enjoy.

https://www.youtube.com/watch?v=0kqrVcrwtFE


broke outer cv joint from the original axel.


pia to remove this bolt 36mm bolt, had to use some heat and along breakabar.


remove the outer cover.


cover is off.


cv joint assembly resting in pieces.


good vs bad, left -good cv right - bad cv


using axel grease to lube up the whole thing.


set the cv boot in


clean the shaft from any dust grime or corrosion.


throw the outer cover with bolts to align. give a few tap on the out side until the cover set in place.
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Default 05-27-2020, 01:37 PM

Finally got around to bolt up the m3 subframe, diff and all the other components on the wagon. Got some nice Fortune Auto 500 coilovers as well.

Thank you,everyone for the support.

https://www.youtube.com/watch?v=LsiSpEqYaYY


putting the subframe together.




setting the front subframe bolts in.


setting the sub in.


here goes the lsd.


e46 m3 sub cross member.


adding the top bolts from the vincebar kit.


topping up the diff with fluid.


drive shaft goes in.


old rearend from the wagon, and struts


brembo ceramic brake pads.


garagistic.com braided brake lines.


fortune auto 500 coilover set. :excited:
10k front 12k rear spring rate.






had to cut in to the carpet, just in case if I have to change the rebound.

So far so good, decent progress. Nextup are the driveshaft, custom trans and engine mounts.

As always, appreciate the support.
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Default 05-27-2020, 01:38 PM

Got around to build the Trans mount.

FYI: This is my first time welding, It's not the prettiest thing but it's solid and functional.

Enjoy the build video here

https://www.youtube.com/watch?v=ZW_1tQA5WQI

Here's the specs if any one planning to build it. You may have to make some minor changes depending on your setup.


top view.



side view.



E46 M3 output flange on.



E46 M3 Drive shaft is bolted on.







Engine and transmission are leveled.



Drive shaft is aligned to the transmission.



Trans mount version 1



Tack welding the mount.













Trans mount is on, next up are the engine mounts.
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Default 05-27-2020, 01:39 PM

E46 CUSTOM ENGINE MOUNTS TO BOLT ON N54

Custom bolt on engine mounts are done.

Check out the video
https://www.youtube.com/watch?v=rPIIK7Vx4zU


Engine bolt plate cut out.


Driver side mount mock up.


Tacking up.


Welds are not pretty, but getting better.


High tech design technique.


First design, didnt work. had to do some modifications.


exhaust mount is ready. It was a PIA to get it right, but worked out.

check below for tech drawings, I'll try to upload the actual files as well.
Hope it'll help others. Make sure to test fit, you may have to do some minor adjustments.











mounts are ready. as usual got the blue paint on.


I ran in to few issues with engine fitment. Got to modify the chassis rail a bit to
allow space for charge pipe from rear turbo. I'll have to modify the down pipe from the front turbo to clear the space between the engine and the subframe.

Furthermore, I decided to go with E90 heater core and e90 dash while mending the engine bay for the charge pipe. SO I STARTED TO CUT INTO THE INNER FIREWALL OR WHAT EVER YOU CALL IT> :idea:

so more to come on that.

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Default 05-28-2020, 10:29 AM

I hope you are putting your talent to use, beyond our prehistoric vehicles.

I skipped reading some in the middle, but I hope your day job is a design engineer for NASA or equiv.

Epic effort! My hat is off to you!




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Default 05-28-2020, 05:56 PM

nice work and great idea. thanks for sharing with the community. you're very talented
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Default 06-03-2020, 06:17 PM

I got a controversial update / rant.


A lot of people have been asking me about electronics, interior and cluster for the swap.


After a lot of consideration I have decided to go with E90 front interior on E46 chassis with all / most electronic aids and heater core from E90.


I started this post as a controversial, since I got mediocre comments on Facebook when I posted the update. Some loved the idea, and others hated it. At the end it boils down mostly to personal preference.


I personally love the E46 dash with its driver oriented and sleek design.
However, when it comes to the build I have to make the most logical and beneficial decisions for me.


Retaining the E46 dash would mean buying more parts to make it compatible. ( 5 series ac compressor, custom ac / heater lines, standalone harness ,custom cluster modification and etc)


However, I was able to modify the E46 inner firewall and custom fabricate a dash cross bar by combining E90 / E46 cross bar to mate the E90 dash to E46 chassis. I'll be using the E90 steering column top section and e46 bottom end as well, By doing so I' m able to use most of the hvac components from E90, retain steering wheel button functions and I hope I can integrate all dash / interior functions from E90 as well.


The Rant.
First of all, I'm truly grateful for the support from the community, and I thank you all from my heart. this is just about a small fraction of people who are lingering around behind the screen.


I get it everyone has their own preference and opinion. What I do with my build is my choice, it's my hard earn $$ and I'll have to deal with the consequences of my choices. It may not make sense to everyone financially. So for the purists I'm not trying to do something sacrilege, just trying to improve in a way I can. I'm not trying force at any one to do this.
I'm all for criticism and I do take the advises from most and follow through.
Not an expert by any means, just a regular guy trying to do something that I love on the weekend.
So If you own car you can comment on the car and so on its your opinion. If you want to degrade on any ones build ability, you should have at least changed your tire or oil before jumping in. Talking is the easy part, doing the work and following through is not so much. It is ok if you don't support the builds, just don't demotivate the person who is doing it.


PS:
( I have to figure out a way to integrate e46 window/ mirror control with E90 interior. since, e46 has it on center console and E90 is on the doors.)


I'm hoping to get a video out soon, unfortunately, I have been diagnosed with BPPV so taking a couple of weeks off till it goes away.



cut out for the E90 heater core.



E90 dash in E46 chassis.
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Default 07-15-2020, 05:07 PM

Did some fab work in the engine bay to make space for the N54B30 Twin Turbo charge pipe and E90 heater core fluid lines relocation.



Check out the video on below link

https://youtu.be/z55aQBIfN9M



Mocking the charge pipe location








Cleaning and cutting the frame rail to make space for the charge pipe. I tried to avoid cutting in to any stress points of the rail.




hammered the sheet metal in to make space.








I kind of went Jeremy Clarkson with the hammer.

It was a bit too much I was able to pull it out a bit back after this.

You should be able to get away by tapping in about 1/2 inch into the frame.








got some cutouts from 18 gauge sheet metal and welded in for structural rigidity. Still learning to weld with my flux core welder, so the weld are not going to win any awards.






primer for protection, and a layer of panel bonding epoxy for added protection and rigidity.


https://i.ibb.co/FstYjGN/E90-heatercore-test-fit.jpg

E90 heater core test fit.


https://i.ibb.co/k2N2s2S/heater-core-cut-out.jpg

cut out for E90 heater core lines and a/c lines.




welded in sheet metal to close the E46 stock A/C line cut out.




Primer and 3m panel bond




All done, got to do a bit of cleaning up in the bay now.
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