I just wanted to save this somewhere. It's a work in progress.
S54 broken down
The wiki does a fairly good job at laying out the problem area's....
Please read this thread prior to procedding to work on your car. Ask if you have questions about properly supporting car.
1. Keep up with Service I and service II inspections. Early preventative maintenance is key at maintaining longevity.
2. Change oil with BMW LL-01 approved oil every 7000-9000 miles. Intake filter and in cabin air filter every 15000 miles.
FYI...WIX oil filters are not OE/OEM and one should go with Mahle or Mann...easy to find, too.
3. Suspensions on E46 seem ok for the first 100,000 miles...but after that most swap out, due to suspension getting tired and fatigued. This also depends on driving style and whether or not you're lowered. Additionally make sure your tires and alignments are up to stuff, as driveability is really affected by these two maintenance items.
CONTROL ARM DIY = http://forum.e46fanatics.com/showthread.php?t=421918
Control Arm Review by FCPGroton
4. Brake pads/rotors seem good for the mild mannered driver out to 100,000 miles....but is solely dependant on driving style.
5. FSR (Final stage resistor) for the blower motor seems to fail regularly. This will be indicated by blower motor acting erradically
6. Batteries last 5-7 years. A lot of info in post #27 and #28.
7. Tranny and diff fluid should be swapped no later than 100,000 miles as BMW re-defined "Lifetime" as 100,000 miles. After that...I think most recommend around 30,000 miles to be safe.
Manual transmission fluid change
Automatic transmission fluid change.
8. Haven't heard of too many subframe issues with ZHP's but there was a class action lawsuit last year, and it seemed most affected were 99-02 E46's.
9. Lower intake boot developes tears/cracks due to design and high temperature's.
10. ICV does become dirty and needs to be cleaned with carb cleaner. Inspect upper/lower intake boot, and inspect DISA when doing this.
11. DISA valve failure due to design flaw.
11.5. DISA o-rings and DISA repair kit
The resonance system provides increased engine torque at low RPM, as well as additional power at high RPM. Both of these features are obtained by using a resonance flap (in the intake manifold) controlled by the ECM.
During the low to mid range rpm, the resonance flap is closed (i.e., the flap is actuated by alternator voltage such that it is held vertically against spring tension). This produces a long/single intake tube for velocity, which increases engine torque.
During mid range to high rpm, the resonance flap is open (i.e, the control voltage is reduced to zero which causes the flap to return to the horizontal rest position due to spring tension) . This allows the intake air to pull through both resonance tubes, providing the air volume necessary for additional power at the upper RPM range.
When the flap is closed, this creates another "dynamic" effect. For example, as the intake air is flowing into cylinder #1, the intake valves will close. This creates a "roadblock" for the in rushing air. The air flow will stop and expand back (resonance wave back pulse) with the in rushing air to cylinder #5. The resonance "wave", along with the intake velocity, enhances cylinder filling.
The ECM controls a (magnetic) solenoid valve for resonance flap activation. At speeds below 3750 RPM, the solenoid valve is energized (with alternator voltage at the harness connector) and vacuum supplied from an accumulator closes the resonance flap (where the vacuum accumulator is apparently a one-way flap valve with a 1/16" entrance hole in the side of the DISA) . This channels the intake air through one resonance tube, but increases the intake velocity.
When the engine speed is greater than 4100 RPM (which varies slightly - temperature influenced), the solenoid is de-energized (i.e., the harness control signal goes from ~13.8 volts DC to zero volts DC) The resonance flap is sprung open (by spring tension), allowing flow through both resonance tubes, increasing volume.
12. VANOS software replacement due to BMW using incorrect material for seals on VANOS pistons. (BUNA-N vice Viton)
I would have 1qt of whatever oil you use, and permatex to go along with the below.
NOTE: The easily broken parts....have never been broken by me...after 7 vanos jobs.
I only get the RED items below when doing this job.
-Double vanos seals repair kit (6-cyl) (BS001) $60/each (www.beisansystems.com),
-Vanos gasket (11-36-1-433-817) 6.73/each
-2 x vanos oil hose/pipe washer (32-41-1-093-596) $.25/each
M52TU & M54:
Valve cover gasket replacement parts:
-Valve cover gasket set (< 09/02 11-12-9-070-990, >= 09/02 11-12-0-030-496) $34.26/each
-15 x valve cover bolt grommet (11-12-1-437-395) $1.73/each, oil fill neck gasket (11-12-7-526-447) 2.29/each
Easily breakable parts:
-2 x vanos piston bolt (11-36-1-748-745) $1.42/each,
-4 x engine cover bolt/nut cap (11-12-1-726-089) 3.27/each, (E39 2 x, E46 1 x)
-Fan shroud rivet (17-11-1-712-963) $.27/each, E39:
-Radiator overflow neck (17-11-0-419-132) $1.67/each
-Easily lost parts: 4 x engine cover pad (11-12-1-730-352) $1.98/each
Valve cover gasket replacement parts:
-Valve cover gasket set (11-12-7-521-009) $63.05/each & (11-12-7-521-010) $17.52/each,
-15 x valve cover bolt grommet (11-12-1-437-395) $1.73/each
Easily breakable parts:
-2 x vanos piston bolt (11-36-1-748-745) $1.42/each,
-Fan shroud rivet (17-11-1-712-963) $.27/each
OPTIONAL AND/OR PERFORMED AS NEEDED:
The anti rattle kit install will require the kit from beisansystems, an impact wrench, socket, and soft jaw vice liners, that can be procured through the beisan site.
***HERE IS THE PROCEDURE***
13. Do plugs when you do VANOS. usually good for around 100,000 miles. Only do coils if indicated by misfires and OBDII codes.
14. CPS (Camshaft Position Sensor) failure seems pretty regular.
15. Coolant system design flaws promote changeout prior to 100,000 miles (This includes Upper/lower radiator hose, T-Stat, Temp sensor, water pump, expansion tank, coolant)
16. Belts (2) and pullies (3) should be replaced prior to 100,000 miles.
17. E46 taillight ground issue. This will be indicated by a BOW for a short period of time, which can be cleared by turing lights on....then off.
18. Strut tower mushrooming can be avoided by purchasing re-enforcement plated from Turner, or by buying a strut bar.
19. Oil level sensor failure. I have heard of this issue many time. Indicated by Oil level light coming on after startup, then clearing approximately 1 minute later. Oil level will be steady during this.
20. Pillar felt sag. This is a common issue. Replacement is pretty cheap...but even cheaper is the DIY.
21. Power Steering flush and MAF sensor cleaning.
22. Power steering pump and reservoir replacement.
23. CDV DELETE
24. Window Regulator. Failure is very common on E46.
25. Sunroof repair DIY
26. To find out what options your car came with, look at POST #1, below.
27. Key Re-Initialization
Get in and close all doors.
Turn on the ignition and turn off quickly. (No more than 5 seconds) to start the process. Next action must take place within 30 seconds.
Remove the 1st key.
Hold the key up near your left shoulder (this is so it is closer to the remote reciever antenna - someone else suggested this).
Hold down the unlock button (which is button 1 on my key) and press the lock button 3 times (center button on my key). Release the unlock button and the doors lock which confirms the operation.
Quickly repeat steps 4 & 5 for key #2 etc.
If it does not work, try doing the keys in opposite order. Key 2 then key1, vs 1 then 2.
Remember to alternate your keys from time to time so that you keep the batteries in both charged. Some have found success with placing the key into a rechargeable toothbrush charger overnight as well.
Another thing you can do is to replace the battery! It's not officially possible (or recommended) for the new key design (2000+) but it can be done.
28. Resetting BMW Oil Service indicator.
29. Tie-rod Replacement
30. E46 Instrument self test
E46 Instrument Cluster Test
31. Rear Shelf/Deck Rattle DIY
32. CCV replacement - By Starless outta St. Louis, MO
33. Unlock and TEST your BMW E46 3 Series OBC Hidden Functions DIY
34. Drug bin diy
35. E46 Water Pump Cap
36. E46 Fuel pump diagnosis and Filter replacement
37. E46 Transmission Mount Replacement
38. E46 Engine Mount Replacement
Here are some good pics.....whist doing this on an ///M3.
39. Automatic Transmission Information
40. E46 M3 rear diff you will need the following.
M3 sway bar (M3 diff will hit your stock sway bar)
M3 half shafts
M3 drive shaft (are you 5 or 6 speed?)
M3 abs sensors
Basically I would go with Quaife at this point if it was me.
Dont the steptronic ZHP have a 3.64 ratio? That is another option if you don't want to spend a ton.
If you can source the right diff out of a ZHP auto or step and do the labor yourself you could do it for a couple hundred bucks. Don't be scared, diffs aren't hard until you start trying to set ring and pinion gears yourself. Which you don't have to do.
Is a rear diff swap worth the money? IMHO one of the best damn mods you can do!!!" Cody Stevensen
Vehicle speed = Engine RPM * Tire Diameter / (transmission gear ratio * diff ratio) --- convert any units as necessary.
Solving for diff ratio, you get
diff_ratio = RPM * circumference / (speed * trans_ratio) -- convert all
So say you're at 3500 RPM in 4th gear (auto) when going 70
diff_ratio = 3400 rev/min * 25pi inch/rev / (70mi/hr * 1056 (in*hr/min*mi) * 1)
diff_ratio = 3.61
41. Fuel Injector Servicing
42. BMW E46 Lower Lumbar Support DIY
43. E46 Engine Removal and Installation
44. DSC / ASC E46 Information
45. Are you installing a strut bar, that does not allow enough strut mount bolt to show (for fastening)?
46. How to wet sand a panel on your E46
47. E46 BMW Performance Strut Bar install Instructions~Attached
48. ECSTuning Brake bleed procedure and information
49. Replacing Broken Fog Light Lens
Incase no one knows here's how to do it.
Tests 1-2 are unlocked. Tests 1.2, 1.2 etc are known as sub-tests. Tests 3-21 are locked but Test 19 is the unlock function for accessing the displays.This should work with your vehicle.
TEST 01. - Vehicle specific data including:
12345 1.0 = VIN
7504 1.1 = Body number
690151 6_1.2 = Part number of cluster
039000 1.3 = Coding/Diagnosis/Bus Index
1102 1.4 = Manufacturing date (calender week/year)
06_110 1.5 = Hardware/software # of cluster (HW:06, SW:110)
1E5_06 3_1.6 = injection status, number of cylinders, engine factor
TEST 19. LOCK/UNLOCK
L-OFF 19.0 =
Displays changes from "L-ON" to "L-OFF" every second. To unlock test functions, press the cluster button immediately when it changes to "L-OFF". Tests are automatically locked when exiting test functions.
TEST 02. - Cluster System Test - activates the gauge drivers, indicators and LEDs to confirm function.
TEST 03. - SI Data
1500 3.0 - Liters
0 3.1 - Periodic inspection days (not applicable for US)
TEST 04. - Momentary Consumption
0267 4.0 = 26.7 liters/1000km
0073 4.1 = 7.3 liters per hour
TEST 05. - Distance Gone Consumptions
0195 5.0 = 19.5 liters/100km
226 5.1 = momentary distance to go (226km)
TEST 06. - Fuel level sensor inputs in liters
237415 6.0 = Fuel level aveg. *LH sensor input = 23.7 liters
*RH sensor input = 41.5 liters
0652 6.1 = Total tank level average = 65.2 liters
0667 1_6.2 = indicated value and tank phase *1 = both sensors OK
*2 = one sensor fault
*3 = implausible input
TEST 07. - Temp. and Speed
032 7.0 = coolant temp. input 32C
245 7.1 = outside temp. input 24.5C
5283 7.2 = engine speed 5,283 RPM
058 7.3 = vehicle speed 58km/H
TEST 08. - Input values in HEX Form
XXX 8.0-8.3 = Hex code, instrument cluster inputs
TEST 09. - Battery Voltage
125 9.0 = 12.5v
TEST 10. - Country Coding
02 10.0 - US 02
TEST 11. - Cluster Code
000003 11.0 = Cluster Code
TEST 12 - Not Used
TEST 13 - GONG Test
Gong 13.0 = Activate gon by pressing buttong (gong response is delayed)
TEST 14. - fault memory (NOT FOR DIAGNOSIS)
TEST 15 to 18
TEST 20. - Averg. fuel consumption - correction factor.
The factor follows previous systems, with adjustment range of 750 - 1250. The adjustment method is new for the base cluster. If adjustment is necessary, enter into test 20 using the cluster button.
The correction factor number is changed by using the sub-tests for the "ones, tens, and hundreds of the correction factor number. The digits will automatically scroll through 0-9 within each group (ones, tens, hundreds).
XXX9 20.0 = Press the button when the correct "ones" position is attained.
XX5X 20.1 = Press the button when the correct "tens" position is attained.
12XX 20.2 = Press the button when the correct "hundreds" position is attained.
TEST 21. - Software reset
reset 21.0 = Reset Software.
OTHER USEFUL LINKS/PICS
WINTER STORAGE OF YOUR BMW
WHEEL RESTORATION ON YOUR BMW
E46 FUSE DIAGRAM
How does DSC work? Read below...
GOT TIRE CUPPAGE?
Question: What is the proper location to rebadge my ZHP?