05 E46 M3 Restoration / Build Thread

[0-60motorsports]

Excellent

[M3_legend]

That’s a clean E46 for its year. Love this thread

[dannyzabolotny]

Great build so far, I'm glad your engine build didn't end up in machine shop hell, I've known way too many people who had to wait for a year or more to get a block done. I'm sure you're stoked to drive the car with this refreshed engine and manual swap, it'll probably feel amazing!

[attbimmer]

I am lucky that I've got some very good machine shops near me. They are busy (especially the crank shop), but they are up front about it and very responsive.

[attbimmer]

Had a relatively free weekend for the first time in a long time, so got some time on the motor. Starting to get most of the ancillary items back on now. Getting close to where it will be ready to go back in. Somehow I misplaced the 2 bolts that hold on the engine harness to the block, so had to order them. Otherwise everything is going back together nicely.

[attbimmer]

Few more misc parts attached to the engine. I think I'm just about ready to get it back into the car. If the stars align I may be able to do it this weekend.




Also with the last set of parts I needed I got a replacement driver's side mirror glass to address the old one failing. I need to find a passenger side now as well.

[attbimmer]

Last night I got final steps done before the engine goes back in. Reset the clutch and got it, flywheel and trans mounted, starter in and everything into the engine hoist. It is quite hot right now even at night so got all that done late at night so it is ready first thing in the morning to go back in.

[attbimmer]

This morning cleaned off the engine bay again and bit and we are ready to go.





Once it was fully in I started connecting a few things before it eventually got too hot. Got the driveshaft and shifter connected underneath. Power steering is put back together and torqued all the subframe bolts.




Also for the first time we have a real gear shift in the car.

[RockyMtnM3]

Congrats, awesome work! You have to feel pretty great walking out and seeing this.

[skylinekin]

Nice work!

[attbimmer]

Was amazing having a mostly free weekend. I think it is the 2nd one this year. I spent a little of that time getting more of the engine bay together. Got pretty much everything connected on the engine and got the intake manifold back on. Part of me really wants to straight to a csl air box, but on the other hand I am a little curious to see how the car is with all the dinan parts. I remember when all these parts were new at dealers. I know there are mixed feelings on dinan, but it is cool to me to see one with so many of their parts after 20 years still together.

Speaking of the cal box though I did discover that the car may have had one in the past. I found a cut wire by the dme and a 2 pin connector spliced in. When I looked to see what pin that was on the dme, I found it was for intake air temp (yellow/blue). The wire from the maf was just left there floating. Seems like it would have been for a separate intake air temp sensor that is used with a csl box. I reconnected the wire to the maf for now, but that makes me a little curious as to what software is actually on the dme currently.

I also got the underbody heat shields and the full exhaust back on and bled the clutch. Most of these are all nice easy jobs now and can just crank through them. That is one of the upsides of taking everything apart. You can reassemble in the most convenient sequence where everything is easy to get to. Also very nice when everything is clean.

I ordered a few remaining filters and some break in oil. Next week I should be able to get the rest of the front end together.

[attbimmer]

Finished up a few small things under the car this evening. Changed the fuel filter and connected the fuel lines and put back on the underbody covers and aluminum brace. Got the car back on the ground again and tomorrow will move it inside. Pretty much everything from the front of the engine back is together at this point.

I also got some new lenses for the headlights as well as new corner/side lights. Really nice that these can be ordered new still for not much money. The last few cars I did that was not the. Ase for the headlights so I have been sanding them down, polishing, epoxy clear coat, wet sand and polish again. They come out excellent, but it is also nice to just be able to install new lenses. I also see a few small cracks in the current lenses so really it was needed anyway.

[0-60motorsports]

You should get the E9X Wide Angle side mirror glass. Love them on my M3.

[attbimmer]

Alright, the car is back on the ground and in the garage. Starting to get the front end back together and filled the engine with some break in oil.

Just about every time I think I've put in the last order I will need to I find something else I need. Putting on the fan I noticed the fan clutch is toast. Basically just freewheels. So got a new one and new set of o rings for the oil cooler lines.

[attbimmer]

Alright final assembly steps for this initial phase. Got new lenses and rubber for the headlights. Also resprayed the internal black plastic with SEM trim black. Awesome paint that gives great satin finish. Great way to rejuvenate black plastics. For the moment I'm putting back on the beat up front bumper. Will replace it with a new one soon.

The Dinan strut bar had a few spots where is was discolored or shiney vs brushed rom rubbing on the hood insulation. I used a mild Scotch pad that was wet and it cleaned up the bar really well in just a few minutes. Also the side markers were badly yellowed so they were replaced as were the front corner lights. New air filter installed with the intake and the car was filled with coolant and 10 gallons of fresh fuel (tank was nearly empty before and has been sitting for 10 months).

Tomorrow I'll do the coding for the SMG to manual conversion and then should be able to do the first start of the engine.