Robs E46M BRG Street Build

[robgill]

Another SMG conversion item I knocked out is building a wiring harness for the clutch switch install. I hate splicing wires and wanted to do this with all the correct OE connectors and pins. I also wanted 100% functionality of GPS sensor from cruise control. Here are all of the parts I used:

Parts
1 x 61116911072 - This is harness from BMW that has the correct clutch switch connector as well as matching color wires to the body harness.
2 x 61130056960 - Wire that comes with 2 female pins already installed and is long enough to reach the EWS and DME
1 x 61138364833 - Elo-Power pin plugs into an open slot in the DME box connecting to the GPS sensor
1 x 61136925611 - 4 pol connector to extend body harness to brake switch without splices
1 x 61132359994 - 4 pol connector to extend body harness to brake switch without splices
4 x 61131383672 - Male pins
4 x 61132360043 - Female pins

Tools you need:
90 degree Pick tool to de-pin connectors
Wire stripper
Crimp tool



The basics of the wiring from the black clutch switch connector are:

Pin 1 - to Brake Pedal Switch Ground
Pin 2 - x60002 Pin 20 DME or direct to Gear Position Switch
Pin 3 - to Brake Pedal Switch (12V)
Pin 4 - to Pin 8 in EWS

Building off this excellent DIY; Instead of splicing into the the brake pedal switch wires, you can de-pin that connector and then re-pin with those wires connected directly in the pin:



This then allows you to add a 4-pol connector that goes from body harness -> short extension -> brake switch -> clutch switch -> EWS/GPS/DME. Some additional detail:

1. Depin blue wires from purple and blue connectors 61116911072 using metal pick tool
2. Depin pin 2 black connector (blue/brown) wire
3. Insert 61130056960 into black pin 2
4. Replace other end 61130056960 with 61138364833. This assumes you are using GPS (Alternative is to leave female pin that goes directly to DME)
5. Depin Pin 4: Bl/Sw (Blue w/Black Stripe) replace with 61130056960. Plugs into the female pin into position 8 in the EWS connector
6. Insert 4 original wires into 61136925611
   1. Pin 1: Br/Sw (Brown w/Black stripe)
   2. Pin 2: Bl/Br (Blue w/Brown Stripe)
   3. Pin 3: Vi/Ge (Violet w/Yellow Stripe)
   4. Pin 4: Bl/Sw (Blue w/Black Stripe)
7. Trim wires to a couple inches long then insert into 61132359994
   1. Pin 1: Br/Sw (Brown w/Black stripe) + Br/Sw from clutch switch
   2. Pin 2: Bl/Br (Blue w/Brown Stripe)
   3. Pin 3: Vi/Ge (Violet w/Yellow Stripe) + Vi/Ge from clutch switch
   4. Pin 4: Bl/Sw (Blue w/Black Stripe)

Completed harness! All plug in play no splices.



One last note here on the clutch switch. Lots of info in the forum on this but here is my basic summary. The correct switch for this conversion that does not require custom coding is 61319122700. Couple challenges with this...

• 61319122700 is no longer available from BMW. It is superseded by 35426876898 which is not correct. If you order from a dealer using 61319122700, you will likely get 35426876898. There is new old stock out there and I got one from ebay. Just make sure they confirm it is 61319122700.
• Also 61319122700 is a lot of times called the "brown switch". It is not always brown... I have on that is black. What matters is the part #.
• The easiest alternative that is available to is 61319122701. 61319122701 is the euro version and has one tradeoff, it does not support that clutch safety feature (clutch in to start car). So you have to code that out of the EWS. If you just plug in 61319122701 the EWS will not allow the car to start.

[robgill]

Back at the cold garage, I've started on some side projects. In preparation for the SMG to 6spd conversation I finished up the pieces I can do while not having access to the car. First was all the work on the transmission. Got the converted bell housing back and installed. Small beed of Loctite 5970 always works well for me on these (also the rear diff cover).





Some grease on the reverse arm roller bearings to hold them in place. Sometimes you have to jiggle the arm with a screw driver to get the housing to slide on.



While I was in there also replaced the front seal, guide sleeve and fork pivot. Tapped it in with a 36mm socket.


Old sleeve pretty worn:


With the bell housing back on, moved onto the various detents and GPS sensor. Tapped new threads for GPS sensor and installed with new detent spring and Thrust/Detent pins some thread sealer:



Also replaced the 1/2/3 detents that are on the top of the trans. Help full kit from FCP Euro with all the parts.




And lastly a new Guibo! Fully refreshed transmission ready to be installed.

[robgill]

Been a little slow over the holidays with a lot of travel and a cold garage, but slow progress is being made! Stopped by Marios yesterday and they have the orginal front and rear glass installed and have started the final wet sanding and polishing. Fingers crossed I'll have it back by end of the month.

[robgill]

I forsee an Evolve airbox being fitted to this motor

A British made box for BRG would be apropos

Thanks for the help on that, I now have 2 Evolve boxes! The box on my track car is getting refurbsihed by Evolve and Im considering tinting that one to have a kevlar look similar to this:



Love the way that looks with the green!! In the meantime the newer box is swapped onto the track car. I'll make a final call on which one goes on BRG after I see how the tinting turns out.

[Tbonem3]

I forsee an Evolve airbox being fitted to this motor

A British made box for BRG would be apropos

[Gt4]

For the nasty BMW waxy spray, I used CRC Brakleen red can brake cleaner and a window scrapper for years. You can also try to use a heat gun, it should help too.

[robgill]

Fast start at the paint shop has slowed down a bit 😆. Still needs final cut and polish so hoping to have the car back before end of year! In the meantime I've been knocking out random jobs and cleaning trim. Sooo much cleaning...

All of the underbody plastics are in pretty good shape so gave them a good scrub with por 15 degreaser. That got most of the road grime off! I'm still working on some of the rear panels with that nasty BMW waxy spray.... That stuff is a nightmare; anyone find a product that works on that??

For the fully cleaned parts I then hit them with Meguiar's M5716SP Marine/RV Vinyl & Rubber Cleaner which leaves a nice satin luster.



Also gave the glass a good cleaning and applied some RainX Anti Fog on the interior.



Also installed one of my black friday purchases

[0-60motorsports]

I had the outside vapor blasted and kept the inside sealed. Still debating if I should upgrade it…

I was thinking of doing dry ice but the people who do it said they wouldn't. I'll just have to use some soap and water as I don't have vapor blasting here. Thanks.

No point upgrading it if you are not doing hard track days.

[robgill]

Nice update! How did you clean the oil cooler?

I had the outside vapor blasted and kept the inside sealed. Still debating if I should upgrade it…

[0-60motorsports]

Nice update! How did you clean the oil cooler?

[robgill]

Next I started on the bottom end. Standard rod bearing replacement and new gaskets/orings for everything. Definitely the first time tor had been opened up. Looked pretty good for 80k miles.


No surprises with the rod bearings. I went with ACL bearings from FCP which I have used on both Rosso and my track car.


Back on the top end I've decided to go with a bigger set of cams. Love the 280/272 setup on Rosso so decided to stick with that. Fortunate to pick up a new set from SamGrant951 here on the forum. This is the newer Cat Cam set with an oil bridge and their modified rails and followers. Got the VANOS off and the exhaust hub tabs, chain guide and cam bolt all looked good.



Old cams removed and head cleaned up:


A little tedious inserting the new rails/followers but with some patience got it all back together with the additional oil bridge that brings oil over to the intake side. The custom rockers have more direct oil spray on the cam lobes.


New cams installed! Also new Beisan upper chain guide (RIP Raj)



To finish off the top end I rebuilt the VANOS (freshly vapor blasted) with new Beisan seals, pump disc and cam/hub bolts.





Finished it off by retiming the motor and doing a full valve adjustment. One thing nice about these aftermarket cams is both exhaust and intake lash spec is the same, .25mm. Sealed it up and finished it off cleaned up oil lines, water lines and new valve cover gaskets, cam sensors, and Rogue Engineering VANOS line. Also new water pump and orings set from @wolfn8tr.

[robgill]

With the M3 at the body shop, I've been focusing on the drivetrain. Plan is a full refresh of the motor with upgraded cam and exhaust. Will also be doing a conversion to manual 6 speed. First big project we stripping down and cleaning up the block. Like most S54s the intake side was a little crusty where water can sit. Exhaust side was pretty clean.



My favorite tools for cleanup are a needle scaler from Harbor Fright and a scotch pad on a die grinder. The scaler is awesome for knocking off rust and loose paint.



Once cleaned up I hit the block with some primer / rust converter from Eastwood.



Then used Por-15 for top coat. Good for another 100k+!



All the accessories also got a good cleanup. I'm going to fully rebuild the throttle bodies and get most of the aluminum vapor blasting. Water pump, starter, PS pump etc will be replaced with new OE.



For vapor blasting I used Brooklyn Vapor Blasting in Red Hook. The result on these parts is awesome. Comes out looking new with a nice satin finish. Vapor blasting is still a little gritty so everything thing needs a through cleaning.



With all of the parts back I started reassembly with a new front and rear crankshaft seals.



Then cleaned oil filter housing and some accessories mounts back on. Plus new chain guide bolts/washers, Constant Pressure Valve and crank sensor.

[thegenius46m]

Hell yeah this is going to be epic! If you do a saddle brown or cinnamon esque coloring of the interior this will be incredible. Can't wait to see the progress


Sent from my iPhone using Tapatalk

[0-60motorsports]

Oh Wow that was fast. looking nice.

[robgill]

Paint progress! Went into the booth this morning.