Keith’s E46 M3 build log.

[nytgamgingcs]

Awesome build thread. Are you going with alpha N or map tune for your new airbox?

[Keith_MN]

Awesome build thread. Are you going with alpha N or map tune for your new airbox?

Thanks! Going with a MAP sensor.

[Keith_MN]

Rod bearings done. #2 upper showed the most wear, #5 upper a bit and everything else looked good. '04 with 78k, original bearings. I do have an oil analysis in progress just for fun.


Got the headers dropped and was in the midst of swapping out the CPV oring and it cross threaded going back in because of course it did. Thread was just barely marred, didnt have a die that size to clean it up so opted to just spend the $50 and get a replacement. Always something.



Still have the bottom end to put back together, euro headers to put on, get the subframe back up and then I'll drop the trans to get the bellhousing sent off for machining. When that's out, I can work on pulling O2 wires for euro sec 1...and lots more after that.

[Keith_MN]

Here we are at the last day of February, making steady progress.

Finished up reassembling the rod bearing job. My RH engine bracket was cracked so I pulled that off for replacement. While that was out of the way, I could work on a couple other things.

Last year I swapped out the engine block coolant plug with a 12mm to -6an fitting after seeing bigjae46 post about it. He had used a banjo bolt, I used a standard fitting and then a 90* -6. I got it to fit, but the hose was threaded through the accumulator bracket and there were too many interference points. I removed that and replaced it with a banjo fitting to snug it up to the block, now it fits much cleaner.



And as you can see above, got the new euro headers installed.




Got the bracket replaced, subframe back up & engine mounts back in place.

I needed to get the trans pulled but of course the next thing I did was give my Meisterschaft sec3 a bath and quick polish. I'm not a show & shine kinda guy but something came over me. Peak M3 ownership.
I did weigh it out of curiousity. 38.1lbs on the bathroom scale. I can hear my wife's eyes rolling from here when she steps on it next and sees the last weight, she'll know I was weighing more car or bike parts.





Enough procrastinating... Started working my way around the bellhousing, couple bolts here and there over the course of a week plus whatever other distractions. Didn't have too hard of a time with the exception of #3. That one sucked. Especially as I quickly resigned myself to lowering the subframe again to gain that extra inch. That extra inch plus a swivel link on a wobble extension gave me the angle. Was certain I was going to break the swivel or an extension, had a good half a rotation on the breaker bar in slop but it did the job.





Eagle eyed viewers will note one missing bearing. I found it after 10 minutes of nervous searching.

Stopped at the recycling center yesterday to get a big box to reconstruct into bellhousing size, then it's off to Hill Performance for machining.

Meanwhile I get to continue the MT transformation, put in a new clutch, etc.

Potentially unreasonable goal: Fire it up by the end of March?

To do that, have to finish the mt swap, csl intake, assorted assembly, coding... Good news is that work should finally be calmer for March.

[George Hill]

For the transmission take an old brake rotor or use blocks under the output shaft to stand the transmission straight up in the air. It'll be really hard to lose the bearings and makes lining everything up an easy affair.

[Keith_MN]

For the transmission take an old brake rotor or use blocks under the output shaft to stand the transmission straight up in the air. It'll be really hard to lose the bearings and makes lining everything up an easy affair.

Noted, thanks!


Unrelated, forgot to post my Blackstone results. No surprises, just a reference point.

[0-60motorsports]

Nice build thread.

[discoelk]

The aesthetic of those Meisterschaft section 3s is 10/10 to me.

[Rekpoint]

Coming along nicely! I am also working on headers and a CSL intake right now. I am local

[Keith_MN]

April already.

Got the bellhousing back from George Hill and everything put back together with a new seal, fork, pivot, etc.
Tapped the tail for the gear identification switch. No problem getting the metal shavings out of there with a small piece of towel pushed in. Use a shop vac to suck all the shavings out and if the towel piece is still there, grab it with a needle nose. Easy enough.

Had a friend come over to help me get the trans mated back up to the block. I told him "5-10 min is all I need!". I think it took us two hours. Just had the hardest time getting it to line up but we got there eventually.

Pilot bearing was being a pain so grabbed a "get what you pay for" Harbor Freight puller. 10 minutes with a grinder to give it some actual teeth and it worked like a charm.


Worked on the O2 wiring rerouting. Pretty easy with so much of the stuff out of the way and the helpful guides that have been posted here.


In the process of rewrapping and placement.


Used OEM clips on the heatshield for the rear O2 sensor wiring which keeps them tucked in nicely. Still have to finalize a some routing and placements, but things are well enough in order for a test run.



I needed to bleed my clutch and thought it was a good idea to give the whole system a bleed. I bought this power bleeder last year to use on another project that got put on the backburner, so this was my first time using it. Definitely a tool I wish I had many years ago.
I watched a video or two on it and glad i did, there were some good tips on the comments. The best one for me being: use thread tape on the brass adapter to prevent leaks.



Got the interior back together including an arm rest delete console upgrade. Forgot that they are shorter too, nice to have every bit of available space in the back as I use the car with my son frequently.




Not a big fan of the alcantara boot but choices are slim.



Currently I'm wrestling with the intake. I'm *this* close to using worm drive clamps but I am prettttty stubborn. Ordered a Lisle pliers to make my life easier with these damn clamps.


Watched a video on a Karbonius intake (this one is TMS) and the guy just turned his dipstick w/o bending and it cleared. Thought I could get away with that but no go, so the intake is coming back out and I'll get to bending this weekend.

Decided to change the wiring and ordered the MAP/IAT/MAF v2 harness from Auto3Design for a cleaner install. Already re-pinned the DME so that's ready to go.

Few more little details here and there....

Was recently going through the PO records again and forgot how old these PSS10s are. Installed July of 2006 - 20 years old! So either a rebuild or a replacement is firmly on the list.