E46 318i 2002 auto to manual conversion

This entry is copied from BMWclubMalaysia forum for backup purpose

Hello,

I’m documenting an undergoing project to convert my 2002 E46 318i N42 CKD from auto to manual.

History
Since early October 2011, after rempit session from Penang to Singapore the car transmission started to give warning on the way back. Warning will reset after restarting but would appear again after aggresive driving. There is knocking sound underneath the car (please see video) and gear change is now different. Visiting mechanic he said that gearbox need fixing and would cost quite a sum.

Never realizing this would happen to me, stumped for a day or two then finally accepted reality. So it’s either fixing it up or converting to manual. Decided to go for manual..

Parts searching started : contacted local supplier, and forumer but end up importing the part. Parts ordered and arrived on Feb 28.

Hope this thread would help me and/or anybody

References
http://forum.e46fanatics.com/showthread.php?t=659314
http://forum.e46fanatics.com/showthread.php?t=396320
http://forum.e46fanatics.com/showthread.php?t=855303
http://forum.e46fanatics.com/showthread.php?t=889867

Knocking from underneath the car

EGS/TCU – GS20 error

Code:
E R R O R M E M O R Y R E P O R T
-------------------------------------
Date: 10/22/11 12:07:56
ECU: GS20
JobStatus: OKAY
Variant: GS20
-------------------------------------------------------------
RESULT: 2 errors in error memory !
-------------------------------------------------------------
146 CAN Moment interface
Error frequency : 2
Logistic counter: 16
Error occured 1. times at:
km value 135600.00 km
Changing gear 1.00 0/1
Last change: implausible 76.00 0-n
Engine speed 832.00 rpm
Throttle-valve angle 0.00 %
Error occured 2. times at:
km value 135600.00 km
Changing gear 1.00 0/1
Last change: implausible 76.00 0-n
Engine speed 864.00 rpm
Throttle-valve angle 0.00 %
General error
Sporadic error
-------------------------------------------------------------
48 Torque Converter Clutch - too much slip
Error frequency : 6
Logistic counter: 5
Error occured 1. times at:
km value 137030.00 km
Gear 160.00 -
Gearbox Oil Temperature 111.00 degrees C
SV 1 0.00 0/1
SV 2 0.00 0/1
SV 3 0.00 0/1
TC-clutch closed 1.00 0/1
SV Shift-Lock 0.00 0/1
Brake operated 0.00 0/1
Error occured 2. times at:
km value 137070.00 km
Gear 160.00 -
Gearbox Oil Temperature 108.00 degrees C
SV 1 0.00 0/1
SV 2 0.00 0/1
SV 3 0.00 0/1
TC-clutch closed 1.00 0/1
SV Shift-Lock 0.00 0/1
Brake operated 0.00 0/1
Error occured 3. times at:
km value 137430.00 km
Gear 160.00 -
Gearbox Oil Temperature 101.00 degrees C
SV 1 0.00 0/1
SV 2 0.00 0/1
SV 3 0.00 0/1
TC-clutch closed 1.00 0/1
SV Shift-Lock 0.00 0/1
Brake operated 0.00 0/1
Blocked open
Sporadic error
=============================================================

Car has been resting well..

Parts at its origin location

Parts here – drive shaft

transmission

other stuff and clutch line

unwrapped

knob

shifter

dmf flywheel and sac clutch set

pedal

transmission support

exhaust support and boot

Getrag 220

Manual trans fluid is also for life

friction plate doesn’t have much life left

Release bearing renewed with sachs replacement acquired from Ban Huat Chan

around the house

Pedal work

Started with pedal swap before trans swap.

remove the trim panel above the pedal and found the gong speaker, front

rear of gong speaker

removal of OBD flap is not really necessary

to cut according the line

not a million dollar work

the ews 3

what it looks like under there

finding the hole for clutch master cylinder feed from brake fluid reservoir

found it

brake reservoir nipple to cut, ouch!

brake pedal assembly removed

auto or manual, pedal set side by side. The bracket of both are the same except for the extra and differently shaped pedal

installed

master/input clutch cylinder hose ready

before (single big brake pedal)

after (clutch and brake pedal)

auto trans with three pedal

Installation

the car carried its own conversion parts

arrives at location for transplant

dismantling begun

auto and manual drive shaft difference, the shorter one is for auto. note the different mounting point

auto transmission (autotragic) out

GM box

made in france

auto and manual box side by side

steptronic shifter from below

automatic shifter out

shifting bracket snap into place (part no 25111222015)

manual shifter in

we had a hard time finding a hole for the clutch line so we drew one. I consider this as the hardest part of the work

dual mass flywheel in place

McFir7 and Khairul putting the box in

transmision support difference, the one being held is for manual

manual box supported, note the different mounting point from auto

me and McFir7 working on the exhaust support

auto oil cooler line from radiator disconnected

to get the engine running pin 2 and 8 from egs have to be shorted since we no longer have the autobox. this applies to GM gearbox/system only

GM transmission connector pin numbering on the gearbox side

the car springs to life, the traction control, abs and brake is on due to my wheel speed sensor. airbag light is expected

the magic stick

it took us the whole day to do the swap with some hiccups along the way. experiencing the amount of work involved, it would take me a long time to finish if I can finish at all to DIY this. thanks to the boys of ZF auto, McFir7 and ramsing for advice on the phone.

the car feels much lighter and zippier now. I don’t really like the clutch pedal placement not being more to the left. One thing to do immediately is to get/make a noise dampener at the shifter as road and engine noise is a bit too much than before.

Programming

Since my NCS-Expert exploration, I am able to reprogram the cluster to think that the car is manual. As a result the transmission error icon disappeared. Read about NCS-Expert here http://www.bmwclubmalaysia.com/forum…2-E46-318i-CKD
There was an error during programming probably because the EGS module is still there, even after programming, there is an error log indicating a foreign device on the CAN bus.

Here is the change I did to KMB

Code:
Generated with NCS Dummy version 0.5.0.5 — copyright © 2011 revtor software


Output       : Trace Differences
Chassis      : E46
Module       : KMB_E46.C06
Trace file 1 : "C:\Documents and Settings\Administrator\Desktop\original\FSW_PSW_AKMB.TRC" (FSW/PSW)
Trace file 2 : "C:\Documents and Settings\Administrator\Desktop\exp\FSW_PSW_AKMB.MAN" (FSW/PSW)
Differences  : Yes


1   2   ID         FUNCTION KEYWORD        FUNCTION KEYWORD TRANSLATION
            ID         PARAMETER KEYWORD       PARAMETER KEYWORD TRANSLATION
        ¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯
        055D       KM_SERVICE_INTERVALL    SERVICE INTERVAL DISTANCE
*           01CF       25.000_km               25000 kilometers
    *       031F       6.000_km                6000 kilometers
        0581       GETRIEBE_ANZEIGE_GANG   TRANSMISSION GEAR INDICATION
*           0001       aktiv                   active
    *       0002       nicht_aktiv             not active

This is the INPA report on the cluster long time ago (when coding to enable OBC)

INPA report after coding IKE, manual transmission!

I was still surprised that the car can still run after the coding..

How the cluster not have the cog-of-death icon anymore

Coding is not yet complete because the EGS is still connected to the bus, the EWS need updating to not check for P/N status from EGS

04C0 PARK/NEUTRAL_EINGANG ENGINE START ONLY IN PARK OR NEUTRAL GEAR
* 0001 aktiv active
0002 nicht_aktiv not active

MK60 need to be set for manual

0588 GETRIEBE TRANSMISSION
01FF handschaltung manual transmission
* 0200 automatik automatic
0201 sequentiell_ag
0202 sequentiell_msport


Few weeks ago I’ve decided to program the car to manual properly after raya. I’m going to utilize the Autologic machine available at the friendly workshop in Gurney.

First is to wire the clutch switch. which was done on Aug 31st break

diagram from WDS. Input to DME would be pin 23 from connector X60004

the box

opened

the DME and connector

disconnected

pulled out

cropped

use the trusty cd drive audio cable to add connection

added

connected back

fish wire into cabin

the grey wire is the reverse switch to activate reverse camera, into the cabin

going to driver footwell there is a tube

fish to driver side

using this switch temporarily

before programming, clutch switch doesn’t register in DME

Programming day

disconnect EGS

Autologic interface

And done, we can see clutch switch input in DME

EGS is out

Happy driving all

Differential work

Right now the car has plenty of pulling power (torque) and losing top speed. This proves a diff change is necessary. Pictures below show the rev before and after conversion at the same speed.

Before, in D

After, in fifth

One thought on “E46 318i 2002 auto to manual conversion

  1. The clutch line is in the car. It is behind the air condition. There is a hole ready for clutch line to come out at left side.

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