Liam821's e46 324i k24/dct/turbo build

[liam821]

So back to the Orient blue ZHP. This car is perfect for my k-swap, while it runs and drives, it needs an engine. I'll continue to daily the red 330i until I finish this blue one and then list it up for sale since there is nothing wrong with it.

First step is cleaning. I need to know if this car's paint is salvageable or if it's a part out/sell whatever situation. I don't mind fixing minor issues here or there but I don't want to do a full body respray.



After the car was clean I was like oh sh$$, the paint is destroyed. Swirl marks, fading, and it looked absolutely awful. Here is a close up.


I did a paint correction on the trunk, one rear quarter, and half the hood. And holy cow, the results were incredible!


The paint looks great


Can you tell which side I didn't do? The "clouds" on the left side is a reflection of the clouds in the sky. The whole front was PPFd at some point, you can see how badly the bumper was. All the cracking is PPF cracking. I'll have to see if I can get that off or if I'll need to repaint the bumper. Also you'll notice that the front bumper is sorta hanging there... the owner's daughter pulled it off by driving over the top of a curb. oops


Super cloudy 40 degrees Oregon day so the paint isn't popping in the pictures, but it really does look great


Only 102,736 miles!

[liam821]

haha I KNOW I have a problem. I picked up this Oxford Green 325i hoping the paint would be okay, but it turned out to be in awful condition. Tons of Bondo on one side, accident although "no accident" on car fax, trunk paint didn't match. I owned it for a few weeks and ended up selling it.

I'm still on the hunt for a CLEAN Oxford Green ZHP and if I find one I might jump on it but we'll see...

A solid 15 footer

[liam821]

Well, it happened again. This is what I get when I'm on the internet late at night. I found a 2005 330i ZHP in Orient Blue with 102k miles in Tucson AZ for a grand. The condition was rough. It had a radiator/coolant problem and the owner's daughter didn't notice and it overheated and hurt the engine. While it runs and drives great but only for about 15 minutes before the pressure in the coolant system because too much. The seller didn't know what a ZHP was nor did he know it was just one of 199 made in Orient Blue, so he sold it cheap, and I got lucky. I called the owner up on a Monday and told him I'd be there Wednesday morning with cash. Left Portland around lunchtime on Tuesday and busted the 1440 mile drive in 17 and a half hours and was picking the car up Wednesday morning.



The paint was rough, lots of swirl marks, and the roof was badly faded. You can see it might be pretty under there somewhere.


Gray interior, not my favorite (sorry Gray interior fans). The rear isn't too bad.


The front, however, is pretty gross. It's like they never cleaned the leather, ever. And


Alcantara steering wheel is so disgusting - it feels like clay!


Nice dent on the hood I'm going to have to deal with


Made it safely home in the middle of that huge winter storm the PNW had without issue. The two finally meet.


I know it's ridiculous, but I have 5 e46s now...

[liam821]

I know I haven't updated this in a while, but a lot is going on in the background...here is the last few months!

I couldn't handle that stupid Pioneer head unit. It was awful so I ripped it out. And holy wiring mess, batman!


So much wiring, it was all removed


I bought an Eonon Android headunit, which for $119, is amazing. I only use it for Carplay, which is does perfectly. I'm still not totally sold on the size, but it's easy to use, easy to see. It is capable of running the Maxxecu MDash Android software, so it can serve as an information screen to help with tuning, gauge readouts, etc


I also replaced the steering wheel with my old M3 Alcantara wheel. So much better. It's amazing what a steering wheel can do.


If it wasn't for the shifter and gauge cluster, you'd never know it wasn't an M3


Speaking of Maxxecu. I finally got my Maxxecu Race. I got the MS43 plug-and-play model. Which you might be asking yourself why, since I won't be using the factory engine. Well, it plugs right into all the BMW chassis side harnesses, and I'm in the middle of making a custom Honda k24 to BMW X60003 engine ms43 harness. So the Maxxecu and k24 engine combination should be plug and play into the factory harness. No crazy slicing of wire, everything plug and play, and all factory functions should work


Plug and play MS43 adapter


Bosch 74mm DBW throttle body, grabbed this from FCPEuro for a Porsche 997.1 Turbo, Bosch part number 0280750474. They're only $137!


Some other goodies have shown up. Artec k20 RWD manifold and AGP EFR vband turbine housing. This manifold is insane. It's beautifully made, compact, almost equal length, cast stainless steel, with excellent wastegate priority, and flows enough for 1000hp.


The manifold and housing aren't any good without a turbo... After much debate, I ended up with a BorgWarner EFR 8374. 62mm capable of 800hp


Fits nicely




Since this car is a 2003, it was missing auto on/off headlights. I kept leaving the headlights on so I replaced the LCM with a new model. I need to replace the front window so I can add the front rain and light sensor, but for now, at least the headlights turn on and off with the key so I don't accidentally leave them on any more


Designed a spacer so I was able to install an e92m3 DCT drive mode selector in the e46 M3 SMG trim.


This is an e60m5 SMG shift knob custom done in black with an alcanata base, on an e92m3 DCT shifter, with ZHP silvercube center trim and e46m3 SMG center trim piece with an e92m3 DCT drive select. I'm going to paint the gray SMG trim flat black, same color as the M3 steering wheel, and the chrome ring I think gloss back to match the shifter


Not very interesting, but I grabbed a e92m3 DCT driveshaft. I'm going to have a local shop modify it so I can use the rear section of the e46m3 shaft, and the front of the e92m3. It will connect in the middle and use a stock M3 center support bearing.


The last few weeks I've been designing a custom new engine harness. A giant spreadsheet with sensor this and that pin to this plug using a TXL wire in the length of whatever. It's a complicated harness with lots of sensors. I've maxed out every input and output on the Maxxecu Race! I'm ordering a CANChecked CanBus extension so I can add a few more sensors. I'll share more soon...

[liam821]

Pulled the valve cover off the JDM k24a RBB3 engine and had a peak inside. Looks pretty clean!


Some wear on the vtec lobe, but everything is very clean








E92m3 DCT is massive!


Used black trim restore (half done, half original) What a difference that made


Did a paint correction as well (left side original)


Paint is actually in fantastic condition






Did take any pictures, because it was an awful job dirty job, but I replaced the radiator and coolant expansion tank. Both were leaking (e46 things). I also took it to Oregon DMV and got it registered so I'll finally get to replace the Washington license plates as soon as my plates come in the mail.

Ordered a few more bits and bobs, the major things I'm waiting for are the misc coolant and oil pieces I need to mate the Honda engine to the BMW coolant/heater/oil cooler. Lots of planning to make sure it goes smoothly. I also think I figured the AC situation, turns out the 2008-2010 525i ac compressor uses the same plugs as the e46, but has a 7 rib pulley just like the k24. I'll get one ordered here soon and design a mount in Fusion.

[liam821]

Picked up more parts!

A large case 210mm 3.25 ratio ring and pinion (H64) from an e34. This will go into a rebuilt e46m3 differential to get the final drive ratio down to 3.25 from stock of 3.62. Why so low? Because 7th gear in the DCT is 1:1 whereas 6th in the 420g is 0.83. The e92m3 DCT uses the short ratio DCT gearbox, and they're short! So you need a longer final drive. Stock e92m3 dct final drive is 3.154, I wanted a little higher than that because a turbo K doesn't have as much torque down low as the torqueless s65 V8.

Here is what the speed looks like in each gear at 3500 rpms.


H64 pinion


H64 ring gear


I don't like the buttons on the steering wheel, so I picked up a brand new upper and lower ZCP steering wheel trim from BMW - I can't believe you can still buy this stuff new! The M-Mode button will be wired into the Maxxecu for rolling antilag.


And because I like cruise control, a Z4 cruise control stalk (DIY here: https://nam3forum.com/forums/forum/m...steering-wheel )


My 330i has heated seats, which we'll be keeping but in the form of heated M3 seats, but I wanted to add a TPMS and a Sport button. You can enable TPMS in the MK60 with some wiring in the non-m e46s (DIY here: https://www.zhpmafia.com/forums/show...e-doityourself ). The sport button will toggle an exhaust valve in the muffler.


Also picked up an e39 wiper stalk with an S button. The S-button will be wired into the Maxxecu to switch between boost maps. I'll probably have the Maxxecu move the tach to 1,2,3,4,5 etc for a second or two to indicate whatever the boost map is set to.

[liam821]

I sold my silver e46 sedan which was in the process of getting a Honda k24 swap because, you guessed it, the k24/dct will be going into this red car. You can catch up on the work done so far here: https://nam3forum.com/forums/forum/m...ct-turbo-build

All the test mounting has been with a k24a4, out of Honda CRV. Well we can't have that. So I picked up a jdm k24a RBB3, the high performance 2.4-liter version!




More to come!

[liam821]

Replaced the shifter bezel trim that was broken in half and installed a new center console I found in my spare parts bin in the garage. I also ordered a $15 cup holder off Amazon, which doesn't match exactly right, so I'll have to order an OEM one but this will do for now. I'm still going to do a center console armrest delete (Had to order all those parts) since I hate that stupid foldable armrest thing, but for now at least I was able to remove that nasty one it had in the car.

I also ordered a center support driveshaft bearing and a new guibo. The center support bearing is DONE, like done done. So we'll get that fixed and might as well replace the guibo at the same time since I'm right there and it's only a few bucks. And sure enough, the check engine light came on (I've only had it for a few days so of course it did) with an error about the secondary air injection pump. Had a look and the hose that connects the pump to the canister had a hole in it and literally fell apart in my hand. So I got that ordered as well. So the car will sit in my garage for a few days waiting for parts.

[liam821]

I was originally planning on painting my silver e46 325i that I currently have - the one I'm Honda swapping - but I decided spending $10k on a paint job didn't make a lot of sense. So I started looking around for another e46 sedan with more interesting paint, I wanted a white or red car or maybe blue. The idea is that I can use this new one and the silver one will go away.

I found this beautiful clean title no accidents 2003 facelift Japanrot red 330i Msport on Craigslist out in the middle of Eastern Washington - middle of nowhere Grand Coulee Washington - for a good price and just had to jump on it. So my daughter and I drove out there to meet the seller and I drove it home. The plans for it right now are fixing/maintenance/paint correction. I'm not sure what engine combination this car will have yet, I guess we'll see. But I can tell you the m54b30 and automatic transmission will be going away. (see thread above with the silver car)

Here is the car at the seller's house:




After all the paperwork and paying my daughter and I headed into town to find some dinner. Her manual 325i hiding behind mine.


The car was pretty disgusting. The interior was grimy and sticky, exterior super dirty. The paint is gonna need a bit of paint correction, but I think it's salvageable.

Checkout the grime!


Check out all the dead skin on the leather shifter, 🤮


After a few hours of cleaning, the interior was as clean as it was gonna be




Next was removing the bubbling window tint. Personally, I think e46's look way better without the tint anyway so it won't be replaced.




I had a scare on the way home that the fuel door was stuck closed, but it turned out that the fuel door ejection thingy was broken. I had a spare in my parts bin, easy to fix.


The car hasn't moved much in the last year and mouse made a nest on top of the engine, lovely. At least they didn't get inside!


A Bunch of scrubbing later...looking better!


The first wash! Hey there's a car under there!




Japanrot red and our Melbourne red i3s




So what's next? More interior cleaning/replacing. It needs a new guibo and center driveshaft support bearing, so those are on order.

[liam821]

So I keep buying and selling e46s - we're on the 5th since I've started this project and making new threads each time is stupid. So I'm going to combine them all into this one and delete the others. Hold on!

[liam821]

And just like that, it's GONE! The short version is while I really want to do the M3 widebody (fenders/hood etc) on the sedan, I don't want to drop $15-20k on paint and bodywork right now. And I'm not much of a silver car guy. Thankfully I found my Japanrot red 330i msport and will be putting my k24 package into that car.

A nice guy from Vancouver, WA came down and picked up my silver shell and is going to turn it into a pro-drift car with an LS.

The last picture...

[liam821]

Does the app your using use the front or rear LiDAR?

You can use either one, the front lidar sensor is more detailed but not as wide and extremely hard to use because you can't look at the screen very well when you're taking a scan. But the rear one is more than detailed enough for most car part design or 3d model or objects.

For instance, here is a fountain my wife liked. It's about 20" tall. From the scan you can directly 3d print it or import it into Meshmixer or Fusion to modify it.

[Bry5on]

The iPhone LIDAR is pretty garbage for scans in my experience. The rear LIDAR is useless for anything other than walls in your house and the front one doesn’t map very accurately. Photogrammetry scans seem to come out way better.

Very cool project build you’ve got going here, I hope you corner weigh it when it’s done!

[Obioban]

Yeah, It's used for FaceID and basically nothing else.

Does the app your using use the front or rear LiDAR?

[liam821]

It's funny how the iPhones have LIDAR, and it gets used for... almost nothing.

Yeah, It's used for FaceID and basically nothing else.