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05 E46 M3 Restoration / Build Thread

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    05 E46 M3 Restoration / Build Thread

    Hi all,

    After finishing an F81 build last Summer, I've been looking casually for an E46 M3 coupe project. The E46 M3 was the first new car I bought back in 2004. I only ended up having it for a couple years, but have always loved them and that has only grown more over the years. I knew at some point I wanted to get another for a future project.

    I was ideally looking for a competition package car, but finding one that is a good project candidate (ie needs work, but not completely trashed) is not easy. I try to keep my project cars in a spot where I am into them for less than what I had to put into them (not counting my time).

    A few weeks ago I stumbled on an 05 SMG coupe with 140k miles that was listed as needing rod bearings. Checking VIN history showed that it was a local California car, it had been with the same owner from 2006 until early 2025 and it had been serviced regularly throughout. I took a look in person and although it had sat outside for a while recently underneath it seemed to be in pretty good shape overall. All records were available with the car going back to 2006 (a stack of paper about 5" think). The car also had quite a few Dinan parts (including intake, exhaust, suspension, tune, diff, wheels) including a Dinan serial numbered plaque. There are varying opinions on Dinan and I wasn't specifically looking for one, but it is kinda cool to have a lot of their parts are together. There are $20k in receipts just for the dinan parts, which I could never have imagined paying for back then.

    The next day we settled on a price and I had the car towed home. I decided not to even start it as I didn't want to cause any further damage to the motor. Either way I knew I would be taking the engine apart, so not much point. The price was at a point where even if I needed to do a full rebuild I should be ok.

    Anyway, just getting things started and will add more details on the plan and progress as things go.

    Here are a few pics of the day I first looked at it.






    #2
    First 2 major things I'm going to tackle are getting the engine sorted and doing the manual conversion. Since at minimum the bottom end will be pulled apart and transmission needs to come out I'm just going to pull the engine/trans out althougher as one. Given that, I started by taking apart the front of the car.

    Things came apart nicely and overall I didn't find much damage. The 2 aluminum brackets that support the brake ducts and underbody plastic had broken tabs. The overflow return coolant pipe that is notorious for breaking off when you try to remove it from the upper main coolant line, did in fact break right off the moment I touched it. Otherwise though things are in good shape and just need a good cleaning.







    As each section came off, I took them apart further as needed and cleaned everything up. Overall everything cleaned up very well. Even the plastics, especially underbody parts that often get abused are all in really good shape.

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      #3
      I was also able to confirm the car does still have Dinan's front sway bar that was part of their stage 3 suspension back then. The springs are there as well. The koni shocks were replaced with a set of Bilsteins not too long ago. Not sure why the Dinan koni's weren't rebuilt instead, but those are gone at this point.

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        #4
        Shaping up nicely! Good find!

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          #5
          Nice find and Love those wheels.

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            #6
            I remember seeing this for sale in LA.

            Glad it went to a good home it was a great deal!
            2004 BMW ///M3 Carbon Black/Cinnamon 6MT Dinan S2 FBO NA Build
            2005 BMW ///M3
            Interlagos Blue/Black 6MT Dinan S3-R+

            2008 BMW ///M3 Alpine White/Bamboo/6MT Track Build
            2000 BMW ///M5 Royal Red/Extended Caramel 6MT In Progress
            2004 BMW X5 Toledo Blue/Sand Beige 6MT Dog Hauler
            2019 VW GSW S 4MO Platinum Grey/
            Black6MT Daily

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              #7
              Thanks guys. Certainly excited to be back with an E46 again. Just love the overall design in and out and the NA motor.

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                #8
                Just taking parts and cleaning them up is so satisfying. Most people's worst nightmare.😁

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                  #9
                  Ooo, congratulations, I like projects like this. Looks like it has good bones, hopefully the motor isn't too badly hurt.
                  Phoenix Yellow e46m3 Build Thread
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                    #10
                    I'm curious to find out. Sadly last weekend all I had time for was to clear out some space for the engine stand to fit in the back of my garage once it is out of the car and got the car up on jack stands. I removed the aluminum under tray, cleaned off 20 years of gunk and that was it. Will probably be a couple weeks before I'm able to get enough time to get it out.

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                      #11
                      I managed to find 30 minute windows here and there to get the exhaust, heat shields and drive shaft disconnected as well as to disconnect the remaining items on top of the engine. Then this afternoon I got home with about 2 hours of daylight left and got to it to drop the engine/trans/subframe/suspension. Didn't take many pictures during since as is it was getting pretty dark by the time I had it down and was separating the subframe/suspension from the engine. For the moment the subframe/suspension are just lying on the ground under the car, but I'll connect it back up so the car can roll again. I know the engine mount nuts don't need to be that tight, but both top bolts were not even finger tight. The mounts were changed not that long ago at a dealer.

                      I pushed the engine/trans into the garage and took off enough so that I could set everything on the ground temporarily. I also pulled off the SMG mess to get that out of the way ASAP and forget it every existed. I imagine no one wants any of these parts at this point so will likely just dump them.

                      Tomorrow I should have enough time to remove the transmission and get the engine on a stand. While taking the front suspension off I also noticed the stock brake lines are starting to crack. Was planning to swap out the calipers anyway, so will get some new lines in then as well.





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                        #12
                        Nice work so far. In hindsight with everything I've done, I would have just pulled my motor/trans as well, though space makes that challenging.

                        I've got the SMG parts to get rid of as well. I wouldn't trash them, given you're in CA I'm sure you can find some very willing recipients of those parts.

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                          #13
                          Pulled off the transmission. Clutch is not original, but it's been about 60k miles since it was replaced. The clutch disk measures at 8.7mm, which seems to be close to what they are new. Pressure plate and flywheel surfaces look and feel decent as well.



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                            #14
                            Mission accomplished for the weekend. Engine is on a stand at the back of my relatively small garage and still able to fit 2 cars inside. I can now start more easily stripping down the engine indoors at night. Will see what we find wrong.



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                              #15
                              Drained the oil tonight and took off the oil pan. At first look things seemed normal. Didn't see any obvious bits or metallic flakes in the oil or in the pan. The rods all looked the same, with no discoloration. Then I went to wiggle each one starting from the back to the front. I go from one to the next and they all feel solid, I'm starting to think maybe I got lucky??? ...then I get to the last one and sure enough it wiggles and knocks back and forth. No big surprise given I was told it needed had recently developed a rod knock. Glad I decided not to even start it when I was looking at it and brought it home. Will get the rest torn down later to get a closer look at the crank and bearings before deciding next steps.

                              The offending party:

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