318ti.org forum - 330dti build

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- - 330dti build (http://www.318ti.org/forum/showthread.php?t=40771)

Hi all, I have another compact with another diesel conversion in mind. Firstly I know most people are friendly but please no silly comments about why or what for, I love diesels and the torque is prefect for drifting. I've done a few conversions now on my bmw's over the years but still have some questions and any help given will be greatly appreciated.
Anyway so far the 2002 330d donor car has been stripped and i think i have pretty much everything i need from it. As for the compact he old 1.9 8v m43 is out, interior is out and m57 has been dropped into the bay for a test fit after chopping out some of the brackets from coil pack and power steering etc. that were in the way.
my main problem at the moment is... surprise surprise the wiring. I'm used to spending my nights cross referencing diagrams but its the way in which the body system works on the e46 that im not so sure of as the plan is to use most of the e46 loom and body control systems so i still have DSC and some other perks as my girlfriend may have to drive it some time.

decided to start this out as a fresh build thread so will show some pics of the journey up to date which started with a guy on his phone driving head on into my last compact which had the M51 2.5 tds which i have managed to salvage some of the parts from...
This is how i collected the car:
http://imageshack.com/a/img901/8171/svGY6q.jpg

Before the adjustable suspension:
http://imageshack.com/a/img538/5447/QpZeZ3.jpg

The suspension fitted & the front brakes were upgraded with some braided lines and the discs were changed for a drilled and grooved set of E46 300mm discs using E36 callipers and E46 caliper carriers combined with E46 EBC yellowstuff pads.
http://imageshack.com/a/img912/7039/20FFM4.jpg

After replacing the new suspension:
http://imageshack.com/a/img540/1778/oVsydv.jpg http://imageshack.com/a/img908/556/DVWcSf.jpg http://imageshack.com/a/img661/2633/wMxYzY.jpg

Rear brakes were upgraded with some braided lines and the discs were changed for a drilled and grooved set using the bigger E34 callipers and organal caliper carriers combined with E34 Alpina EBC yellowstuff pads.
http://imageshack.com/a/img673/5514/YpU1nM.jpg

short, dark and mysterious... 2 out of 3 isn't bad

The Donor car, 2002 E46 330D M-Sport. No i didnt have any ramps to hand so i loaded and unloaded with my engine crane and ratchet straps:
http://imageshack.com/a/img674/9370/rTqeTg.jpg http://imageshack.com/a/img674/6372/dHROMb.jpg http://imageshack.com/a/img537/90/ukFAzP.jpg

Don't have any more pictures of it stripped but you get the idea.
Removed engine, complete vehicle loom and everything electrical that connects to it; steering wheel, column & rack; brakes complete with ABS/DSC pump, master cylinder, servo, pedal box.

next was on to preparing the compact for the new engine and loom. First the interior was pulled out and then the engine:
http://imageshack.com/a/img674/3431/voLixG.jpg http://imageshack.com/a/img910/8733/T4aKcr.jpg http://imageshack.com/a/img909/5969/Pg6SRq.jpg http://imageshack.com/a/img540/6663/HobMWL.jpg http://imageshack.com/a/img673/3861/ptqPJ3.jpg

Up to date I've fitted the engine just as a test run to see what of the brackets in the engine bay have to be chopped & smoothed and what will be needed, as it turns out pretty much every bracket that was for the petrol engine is useless. Founds that the m57 is a MUCH bigger engine than the m51 2.5L diesel and is a PITA to drop in without damaging anything even after removing the air-con pump and tensioners.
http://imageshack.com/a/img540/7806/480rxf.jpg http://imageshack.com/a/img538/8876/L7mOzi.jpg
http://imageshack.com/a/img909/9434/gJeTus.jpg http://imageshack.com/a/img674/4747/qUKXrd.jpg

It fits! Just with a few problems that need ironing out also still awaiting the new engine mounts so its just sitting a little low on the subframe but she looks pretty in there.
http://imageshack.com/a/img674/4288/PlLJu7.jpg

One problem I'm trying to solve is I'm using the complete e46 loom and body control module which seems to communicate with the airbag module. Does anyone know if the e36 airbag module will work or communicate properly with the e46 body control module or would it be possible to reprogram the e46 unit to work without the side or curtain airbags as the e36 does not have these. using the e46 unit would be easier otherwise i still have to chop out and splice in the e36 airbag loom and connectors. I have the BMW tools Software including INPA, NCS-expert etc. but have never looked into if this can be used to reprogram airbag modules in this detail. Any advice would be greatly appreciated

This thread need pictures... like a lot of pictures.

Bracky, your pictures aren't showing up... looks like they are hotlinked from another forum.. Please repost or update the picture source.

I wanna see the pics... So I can follow what you're doing. 👍 ☺

ok sorry people will sort them out tomorrow. Thanks for the heads up

Pictures should be working now, will get some more as i finish smoothing the engine bay and fabricating the fuel filter/cooler mounts
some pics of the finished ABS/DTC pump bracket before it goes in never to be seen again
http://imageshack.com/a/img905/7489/Ai4qG8.jpg http://imageshack.com/a/img907/341/hz3YaT.jpg

Sweet. Way better with the pictures. 👍
Creativity of using what you had to lower the car from the flat bed. I used my bobcat tractor 🚜 I had in the backyard to take out my old motor and put in the new motor with transmission.
You should try to take off the front nose panel to make it easier to put it in and out while you do that fits, etc.
I'm guessing you'll use the donor car wiring loom for the project?

I also put the car on the truck using the crane and ratchet straps, it was a scary 3 hours!
I don't have much time and needed to see how much clearance so didn't remove the slam panel. Yeah using the entire E46 harness including car interior harness. engine swap side is easy as I've done a few already in BMW's but this wiring project is more than i had planned, the only connector that's the same is the radio and i have to find space for all the modules etc. Will post some pics of the wiring mess later

still not seeing photos.. i would suggest using photobucket bracky...

Not much to say at the moment as I work so much and been preparing for Christmas but I'm currently preparing the engine bay for fresh paint then I can drop the engine back in for the final time. Other than that I've just been doing the odd quick job preparing the engine, ie. egr blanked off at the exhaust end, had a friend machine a new egr valve pipe without the valve, removed the egr heat exchanger, bridging the coolant hoses, new pcv valve and vortex filter, swirl flaps blanked plus the manifold and ports have been cleaned.
Will add to this with some pictures in next week or so
Also i've just had to change from flickr as they lost all my pics, just updated them all on here with new links from imageshack. can someone just confirm that they are visable?

Images are visible. Very cool project. That thing should have a good torque/weight ratio. How much lighter is your Ti with a m57 compared to a 330d? Do you expect the fuel consumption to be better or worse than the 4cyl 318ti?