Cockroach Individual M3 6/2 AST DIY, 70C Thermostat

[samthejam]

I would be most concerned about the shift arm bushing bracket. No issue using a used one like you are but with the rear tab mostly cut off I think you are going to struggle to fasten it securely. I would consider getting another one unless you are going to weld it and if so pull the carpet so its doesn't catch on fire.

Yes the plan is to weld it and try and make the carpet not catch on fire. I think I am going to just remove the center console and cut accordingly. Then just place that piece of carpet back in.

[George Hill]

I would be most concerned about the shift arm bushing bracket. No issue using a used one like you are but with the rear tab mostly cut off I think you are going to struggle to fasten it securely. I would consider getting another one unless you are going to weld it and if so pull the carpet so its doesn't catch on fire.

[samthejam]

1st. For people who don't know anything about coding: The central coding key (ZCS) or vehicle order(FA or VO) is like the DNA of the car. The build date, basic equipment and optional equipment are listed inside here. It's saved redundant in 2 modules and has one simple funcion.. The computer that's going to program or code the module(s) reads it and then determines how to deploy the software/coding to suit that specific car.\

2nd. Because of the vehicle order only being changed for manual transmission, you should only code the relevant module(s) after you write the FA to the modules storing it, so in this case you should have only coded the kombi (AKMB) instead of the whole car and you would be all set. Processing the whole car can be quite dangerous. As failure to communicate with a module during coding actually can destroy a module.. ask me how i know Because of that you should only code modules that actually need to be coded and leave the rest alone, to reduce the risk

[samthejam]

or example changing Vehicle Order (VO), and adding/removing options from Modules. NCS Dummy helps understand what the options mean in English.

Steps:

1) Using NCSExpert, Remove $793 (this is the SMG option by the way) from the Vehicle Order in AKMB and ALSZ modules then write the new Vehicle Order back to the AKMB and ALSZ modules.

2) Modules to Code With NCSExpert, note in brackets is the NCSExpert name for the modules)
- DSC (DSC), change from SMG to Manual
- Instrument Cluster (AKMB) removing any SMG options, then adding any manual options that are available to select
- Immobiliser (AEWS) - remove press Brake Pedal To Start option
-
NOTE: As stated above, NCSDummy makes doing the changes above much easier

https://www.youtube.com/watch?v=FiBr1h9j0bU

[samthejam]

Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr

Ladies and Gentleman, I believe it is time...

Almost everything here is used, so that's fun but why new when used will do. I refreshed the shift bushings with OE at least.



I believe I have everything, I did the GPS delete by manually editing the bin file. Than Jay popped it into his Ecuworx for me and did the rest of the manual changes needed.

I modified the .xdf for this and here is some notes I have as the ones in the manual swap thread were kinda confusing.

MSS54HP .bin Modications:

1) Modify K_SKRAFTS_CONTROL to 0x02

• Location: 0x4028
• Edit: Set to 0x02 → 2 (default is 0x01 → 1)
• Purpose:
  • The DME currently treats the clutch sensor and Gear Identification Sensor as one, since they are wired in serial.
  • This setting aligns the behavior with how the Z3M is wired, where the clutch switch is directly connected to the DME.
  • With this change, the DME will recognize that the circuit can still be closed even when the car is in neutral with the engine running.

2) Modify K_S_GANG_LL_ED to 0xFFFF

• Location: 0x5952 on 2001/2701
• Edit: Set to 0xFFFF → 65535 (default is 0x0032 → 50)
• Purpose:
  • This prevents the DME from throwing an error when the car is idling with the clutch engaged (up).
  • It essentially adjusts the logic for idle behavior, ensuring that the ECU does not falsely detect an issue when the car is stationary.

3) K_MD_MIN_VERH_KRAFTS

• Purpose: This parameter defines the minimum torque threshold required for certain powertrain functions to be active.
• Edit: Set to 0xA0 → 160 (default is 0x80 → 128)
• Location:
  • 0x67E0 on MSS54
  • 0x88A2 on MSS54HP
• Default Values:
  • US cars: 0x80 (128 in decimal)
  • Euro cars: 0xA0 (160 in decimal)

The plan is to throw it all in this weekend, flash it and see what happens. I am most nervous about removing the Plenum as I haven't done that yet.

[samthejam]

Another unexpected update! This week, while I was at work, I got a call from a friend. He told me he was picking up the alignment machine from the shop where I used to work in high school. The computer was broken, and the owner decided to replace it with a two-post lift instead. He has an alignment guy but doesn’t like dealing with it himself.

Along with that, the owner wanted to clean out the shelves—over a decade's worth of collected stuff—so my friend mentioned that he was giving away a bunch of E46 M3 interior parts.

This happened to be the same shop that stripped out my dad’s M3 years ago. So after helping them load up the (sketchy) alignment lift, I started digging around. The Find


I ended up uncovering:

• My dad’s old rear door cards
• His radio surround trim
• Front Grey ZCP door handles
• Three coupe door cards
• All of his old headliner A, B, and C pillar pieces

The blue bin ended up holding all of these neatly organized. I even found his name on old registration papers, a dealer inspection from 40K miles, and some cigar business cards—all tucked away in the armrest, which unfortunately had broken while in storage.

You can actually see his old headliner sitting up there:


Zcp trim by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr


Zcp trim by Sam DaJam, on Flickr




Zcp trim by Sam DaJam, on Flickr

The rear door cards were the ones I used to sit in when he dropped me off at elementary school. I’ve always preferred the ZCP trim, and since my own door cards had messed-up armrests, I was excited to swap everything over.
Zcp trim by Sam DaJam, on Flickr
Zcp trim by Sam DaJam, on Flickr

Zcp trim by Sam DaJam, on Flickr

Untitled by Sam DaJam, on Flickr
Only one broken clip on his old panel! Salvage Yard Run


The next day, I went to the yard. Out of all the Houston self-service salvage yards, there was only one coupe with a black interior that I knew of. It had been there since January 2nd, so I had low expectations. Sure enough, the manual swap and any decent black interior bits were already gone.

While working on my door cards, I noticed an issue: when it rains, my driver’s door card fills with water—usually a vapor barrier problem. Since I had everything apart, I was able to confirm that was the case.

Then, I looked up at the headliner of the car and realized it was a slicktop—super rare on a 330i with leather interior and electric seats.

I knew I had to grab it.


Zcp trim by Sam DaJam, on Flickr
Hauling It Home


I had to call my wife to bring the Montero because there was no way I was driving home with it in the E46.

With only a T20, 10mm, and two flatheads, I had to borrow a Phillips from someone at the yard. I originally packed light to avoid buying stuff I didn’t need—but when I saw this slicktop, there was no way I could pass it up.

Zcp trim by Sam DaJam, on Flickr

[naskhoda]

🔥 dope

[samthejam]

I got the SSR welded up. I'm not happy with how it got repaired at all but, what're you gonna do.

I also found out my rack had endplay and was binding. So I found a yellow tag from the yard pulled it and installed it, did that Saturday. Sunday I jumped on a deal from Dallas, some AST 4150 installed and aligned the car. Not too happy with them yet but old GCs were very worn out. However the car has now lost how easy it is to get in and drive. So idk what Im going to do yet.

AST and matching ssrs by Sam DaJam, on Flickr
AST and matching ssrs by Sam DaJam, on Flickr
AST and matching ssrs by Sam DaJam, on Flickr
AST and matching ssrs by Sam DaJam, on Flickr

AST and matching ssrs by Sam DaJam, on Flickr

AST and matching ssrs by Sam DaJam, on Flickr
AST and matching ssrs by Sam DaJam, on Flickr
AST and matching ssrs by Sam DaJam, on Flickr

AST and matching ssrs by Sam DaJam, on Flickr


Also ordered the last of the stuff for the manual swap and got a ecu file ready
AST and matching ssrs by Sam DaJam, on Flickr

[M3Garand]

Great build

[samthejam]

Bruh...your road trip was like an old Top Gear episode but without the support truck!

Yeah my cross country adventures can be a bit bold.

Here is my welding my E28 strut housing to get back home after the used Hooisers sheared it at Barber.

[bigjae46]

Bruh...your road trip was like an old Top Gear episode but without the support truck!

[samthejam]

Had another DE. Car did well, blew my expectations out the water in terms of the pace it could do. The high bite front pads were fantastic, huge confidence boost. The 08s work on my E28 but they were terrible for me on this car. I am a big PFC fan, but they just didn't work for me on this car. When these 83s run out, hopefully the 11s will fill the void. I believe DTC-70s would work as well but not a fan of Hawk Pads.

A bunch of 47s with passenger and was able to squeeze out a 1:46.67.



The PB Lap:

External Video

[samthejam]

The total mileage for 2024 was 14,448 miles.

I also didn't realize that this color was so rare. So I should probably look into making it shiny for 2025.



Current Projects for 2025:

- 6 Speed Swap
- Passenger Recaro Profi
- Roll Bar and Harness
- 4 Matching SSRs
- Look into getting Hood Painted
- CSL Front Bumper
- Drive that bitch

[samthejam]

Alright so another update.

Very big update, not in terms of building the car but moreso in sharing the adventures the car has been on.

So the last update was me at MSRH, and that's where this will post will start off but it is the following weekend. It was miserable out, but a good low stress way to test the car out before heading to Road Atlanta.

MSRH is horrific in the wet, there is a 10-15 mph difference between the wet line and the dry line for corner speed. It is an ice skating ring. So there were many sideways moments, but I have done many laps here so I am comfortable in the wet.

I almost got bit here...

https://youtube.com/shorts/JCqtRzrYvLA?si=hvRimtCbGoDnNVDp

It was just cold and wet but I got a lot of laps in. Car looked like it was ready for the big trip. I put some Direzzas on it since they were on closeout and for peace of mind of new tires for the whole trip. Rear pads were paper so bought some new PFC 08s for that. Also aligned it again. This time I did stock toe for the front, I don't really like the feeling of zero toe, but the main reason was to give the tires best fighting chance for all the highway miles.

Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

Anyways onto the Roadtrip. Cannonball to Atlanta, in one shot from Houston. Weren't any issues.
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

Went to the Aquarium and explored downtown Georgia for a bit. jayjaya29 was nice enough to let me stay at his home and use his workshop to do a bit of trackprep. These 265 Direzzas are significantly wider than the RS4s so we needed to do some fender hammering, as the damage from previous owner wasn't giving it enough clearance.

I knew the car would blow sound at AMP, but I was able to get a couple laps. It was miserable and raining. 107db, is what I got blackflagged for.

Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

That evening I did the SAP delete and did a P/S flush as the system was pretty angry.

Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

Then it was time for Road Atlanta. It did dry up after Lunch, but the morning sessions weren't wet. Morning sessions were trouble free.
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

Didn't bother recording with Go Pro. My wife was able to get some external videos.

This event was sold out, so there was a lot of traffic. When it did dry out, I came over turn 3 pretty hard. My instrument cluster did not like this and started acting up all day. Would come in and out, and during one session the tach started touching the oil temp needle so I had to start short shifting. Despite this, I was able to set a new PB, however I was not able to meet my goal of a 1:39.99 here. I had multiple instances where it was showing up on predictable but ran into traffic or cluster would spazz out and distract me.

Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

By the end of the day the cluster was struggling. Braking would make it cut out and only work with dimmer at lowest setting. We still had to go to Charleston to see my wifes family I needed to fix it, but I delayed this by a day to give myself time to sort out the cluster. I put out a WTB for a cluster just in case but took it apart at Jay's that night.

I really didn't think it was fixable but luckily was something simple. Please click the Flickr link to see what it was but basically one of the Capacitors had come off the board with the pad.

Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

Jay was able to repair it for me and cluster was alive again. Also tightened up the shock nut.
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

Following day, Faustino and I did an impomptu run to Tail of the Dragon. My plan was to head to Charleston that night so we would just go to the Tail do one run and come back.

Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

Ended up working out perfectly. We had no traffic. Cars didn't really give any trouble, besides mine the power steering had basically no assist at idle after second run.

One of my favorite pics of the car so far.

Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr


We ended up heading to Charleston at 3am since I was beat. Needed some sleep. We did Atlanta to Charleston, in one shot. I was on fumes when we got there, and first time ever filling up with 91 in my life. I've always had access to 93.

Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

At this point the power steering was crying. Checked the reservoir and yea very bad.
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

Tried to do another halfass resevoir flush to bandaid it along but at this point needed a new pump.
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

I lucked out, there was a M54 X5 at a Self Service Junkyard.
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

I was able to get permission to swap the pump out in a Autozone parking lot. They said I had a hour, I was able to do it in 40 minutes.
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

Parked for the night at her Dad's house.
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

Rest of the trip was all touristy nothing really car related. Went to Convington, Birmingham and New Orleans.

Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

Total trip mileage was about 3000~.
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr


I was having a brake shudder that was pretty bad felt like a rear rotor. I felt it on way back from Charleston. Not sure what caused it but sure enough. I believe just the Metallurgy of these cheap drilled and slotted rotors. Unfortunately I put another used set on because my friends parts car had them. We traded them some stuff for it.
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

Following this finally washed the car
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

I need to fix the cracked wheel so I can have 4 matching wheels.

Also was able to find some NOS PFC 83s for it. Yes you read that right 83, can't imagine how long those have been sitting on the shelf. Threw those in on NYE. Yes I am running the pad clip.
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr
Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

Fall ‘24 Update by Kurvenkamph Motorsport, on Flickr

[samthejam]

So got the strut towers finally welded, they have been cracked since I got the car as well as the Strut brace. My friend was able to tig it in the car with everything still assembled.

Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr

Strut Brace also repaired. It was cracked clean through.
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr


I signed up for an impromptu event at MSRH, my local track. Very familiar with this place, and aren't many consequences here for most places when you push so it's great to feel a car and test it out. I was really low on rear pads, so just wanted to get one test session in. They had some portable curb things to move the apex's which in a couple spots was terrible like into Gut Check and coming out of Keyhole were the most irritating ones.

Untitled by Kurvenkamph Motorsport, on Flickr

Car is super easy to drive though, the new Hotchkis bar was a nice addition. It is at the softest setting right now, might want to stiffen it but the balance of the car is very good. Overall it is too soft so on the 265 Rs4s now it is okay but if I start running fresher Hoosier takeoffs or even RE71RS I am a bit concerned itll be a bit soft. But anyways car was boogie'ing. Annihlated my PB here I did in the E28 on Hoosiers.

Untitled by Kurvenkamph Motorsport, on Flickr

Here is a lab of the PB:

Unfortunately after that PB car bit me and the thermostat went into the water pump. So the car has been running extremely cold, which has been tough to daily drive with since it's finally getting moderately chilly here in Texas. I had a used thermostat on standby, but was debating on going the Anri 70C or motorsports thermostat. Red light of death luckily never came on caught it quick and was able to coast/ limp car into pits.

I had a friend drive me back home to grab the thermostat, as I suspected that was bad since the top hose was hot and bottom room temp. I thought the thermostat froze shut. I brought my spare used water pump as well just in case. Glad I did.

Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr
Untitled by Kurvenkamph Motorsport, on Flickr


I also was lucky enough to have this which I had on hand just for emergency's.

https://nam3forum.com/forums/forum/classifieds/member-services-rentals-products/4125-m3-s54-cooling-system-hi-temp-o-ring-kits

Was able to get the car all patched up with the brand used parts and new orings and it left under its own power.

Untitled by Kurvenkamph Motorsport, on Flickr


Systems check the following day.
Untitled by Kurvenkamph Motorsport, on Flickr


So if you notice all the parts that were removed are absolutely covered in RTV (I hate RTV). Well one connection was not and I think this thermostat has been out for a long time. So when we were assembling everything, the water pump pipe stayed with the thermostat housing. We found out it cannot be assembled like this. So we got the pipe out which took quite a bit of time as it had never been seperated.

Now it's hard to say since my thermostat came out in many pieces. However my hypothesis is the monkey who was in here before and replaced the water pump (2010 date code) as well as the thermostat did not know that pipe needed to be be in the block/head first. He jammed it all together somehow, and this bunged up the thermostat. Since I got the car it had a coolant temp implausible code and then I deleted that DTC. My guess is, it has been like this for a long time but anyways all correct now.



There will be a HPDE next weekend I'll be instructing at will test car more. Then it will go on a long roadtrip and get a day of beating on at Road Atlanta the following weekend.