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E46 M3 (2001-2006) Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006.


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Old Mon, Jul-15-2013, 10:16:46 PM   #31
SteveEvans
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Default Re: M3 SMG pump reconditioning

Quote:
Originally Posted by willoug4 View Post
Steve, this is really great research, and I'm sure everyone with an SMG appreciates your help and advice. Would you agree or disagree with this conclusion, based on my ignorant read of your research: the "resistor fix" is likely to only make that SMG light go off, and won't affect the real problem.
The resistor fix simply masks the temperature sensor error. It's much easier to fit than replacing the sensor, it's cheaper, and won't suffer subsequent failure. The car runs perfectly with the resistor fix in place, and seems to cause no harm. The only known side effect is that the accumulator pressure runs a bit lower, so the pump will cycle more. I guess you'll wear out the salmon relays slightly faster with the fix in place.

Quote:
Originally Posted by willoug4 View Post
Also, replacing the motor that drives the hydraulic pump might be a better solution to the pump run-time issue?
You'll get the 056 error with a brand new pump if the temp sensor if reading over 100 degC, even momentarily, so do the following if you're seeing 056 errors:
  1. Replace the salmon relay
  2. Apply the resistor mod
  3. Deal with any subsequent error codes.

Quote:
Originally Posted by willoug4 View Post
My SMG is working very well, but since I've relocated from a cool weather climate, to a very hot one, the SMG light comes on from time to time, flashes a bit, sets an SES light, then goes out. I'm sure it's trying to run me mad, and I'd like to learn whether the hot weather here ( 109 to 118 F daytime) has truly caused a problem with the trans, so I can fix it. Thanks again for all the good input!
I did the resistor mod at 135K miles. The car has now done 157K and has been fine. As you're seeing temperature related errors I suggest you do the resistor mod if you haven't already.

Steve
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Old Sun, Jul-21-2013, 11:35:50 PM   #32
Soarer20
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Default Re: M3 SMG pump reconditioning

A word of caution if your thinking of replacing the carbon brushes. Carbon brushes are NOT all the same. A soft carbon brush will wear out many times more quickly than a hard brush. The harder brush will wear the comm more. You need to match the factory carbon brushes or your just going to encounter more problems.

I would send the motor to a good electric motor repair shop who has repaired lots of abs pump motors.

This SMG pump isn't that complex but getting the details right is very important.

Quote:
Originally Posted by SliM3 View Post
Just FYI:
If anyone is interested in replacing the brushes, minus a full armature re-wind, here is the website to purchase them L5-5H 5mm x 5mm x 13mm Copper M. I have not done any replacements yet, but the electric motors on the SMG units are basically the same as ABS Pump motors, for which these are compatible.
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Old Mon, Jul-22-2013, 07:42:27 AM   #33
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Default Re: M3 SMG pump reconditioning

We're you able to pull the pump motor with out removing the entire SMG pump? If so can you please explain how?

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Originally Posted by RedM3/4 View Post
Interesting. I'll try to pull my motor again tomorrow evening or Saturday. From memory when I pulled it a week or so ago I don't think mine has that silicon washer between the bearing and the case, but my memory isn't what it used to be! Worst case I'd just put a small bead of silicon caulk at the very edge where the motor meets the valve body, but I'd expect you're already water proof with your light fixture washer.

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Old Wed, Oct-16-2013, 08:20:24 PM   #34
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Default Re: M3 SMG pump reconditioning

It works!!!!!

My pump died completely on the way to work yesterday morning. When the car dropped irretrievably into neutral I connected the laptop and found INPA to be reporting zero pressure. The pump wasn't energising. Clearing the fault made INPA report that the pump was running for 40s and then the cog light came on again. I have a spare salmon relay, but swapping that didn't work. Still no pressure at all.

It wasn't unexpected as the resistor mod I'd made last year only compensated for a dodgy temperature sensor. My recent attempt (HERE) to completely eliminate the temperature sensor seemed to show some promise, but alas didn't last.

I had my local independent BMW specialist replace the pump unit with the one I've described refurbishing in this thread, although I chose to use the original accumulator as I knew that to be OK from my recent monitoring of the pump's ill behaviour.

Works perfectly.

I'll pull apart to the pump that's been removed to confirm that the motor has indeed burnt out as I suspect, and I'll take the opportunity to photograph that seal that the rewind company managed to lose.

Steve
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Old Wed, Oct-16-2013, 09:42:42 PM   #35
SteveEvans
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Default Re: M3 SMG pump reconditioning

This thread is a bit of an extended log of slow progress, but the basics of remove pump, remove motor, get it rewound, replace temperature sensor, refit motor with bearing suitably fitted, install and enjoy, are pretty clear.

If I'm asked I'll produce something more concise for a sticky thread.

Steve
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Old Wed, Oct-16-2013, 09:49:17 PM   #36
SteveEvans
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Default Re: M3 SMG pump reconditioning

Once I've pulled apart the pump that's come off my car for some "before" photos. I can then create something a bit more structured.

Steve
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Old Thu, Oct-17-2013, 02:47:03 AM   #37
RedM3/4
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Default Re: M3 SMG pump reconditioning

Great update! Also be nice to see if the motor coming out is bad.
If you have a way, can you spin it at some RPM to get it to 12v output, or something close? It would be good if we could develop an RPM test for motor output.

ADS
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Old Thu, Oct-17-2013, 07:11:44 AM   #38
SteveEvans
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Default Re: M3 SMG pump reconditioning

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Originally Posted by RedM3/4 View Post
Great update! Also be nice to see if the motor coming out is bad.
If you have a way, can you spin it at some RPM to get it to 12v output, or something close? It would be good if we could develop an RPM test for motor output.

ADS
Removing the motor from the pump removes its end bearing support, so spinning it up isn't an option. Even though the pump was dead in the car, now that it's removed and has been disturbed I wouldn't be at all surprised if it ran if I applied power. Visual inspection of the brushes/commutator will probably be quite conclusive. At 162K miles I think I know what I'll find!

A test that can be conducted on the motor which has yet to fail can be found HERE, however when I hooked up INPA at the weekend, just prior to the failure, my pump was priming just as fast as it ever had, unlike the car in the link here which had slowed. I've read of other cars taking 15s or more to prime. Mine was still only taking 5-6 seconds to go from ~50 bar to >70 bar. The new pump may be slightly faster, but only by a small margin.

Steve

Last edited by SteveEvans; Thu, Oct-17-2013 at 07:22:42 AM.
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Old Thu, Oct-17-2013, 06:48:20 PM   #39
NetFixer
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Default Re: M3 SMG pump reconditioning

When I opened up a motor from a "defective" pump, there was a lot of carbon in it. You think it could cause the motor to bind and spin slowly? I'm wondering if just cleaning it out and putting it back will make it work well again. When I put mine back in it sounded a lot stronger than before the cleaning. The pump in my car is still good so didn't get to test the "defective" one yet.
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Old Thu, Oct-17-2013, 06:52:47 PM   #40
SteveEvans
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Default Re: M3 SMG pump reconditioning

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Originally Posted by NetFixer View Post
When I opened up a motor from a "defective" pump, there was a lot of carbon in it. You think it could cause the motor to bind and spin slowly? I'm wondering if just cleaning it out and putting it back will make it work well again. When I put mine back in it sounded a lot stronger than before the cleaning. The pump in my car is still good so didn't get to test the "defective" one yet.
I'm confused. Are you saying you've taken a pump off your car, cleaned it and put it back? Sounds like you may be talking about two pumps here.

Of course this thread started with me talking about a failure of the pump on my car and then showed the disassembly of another, so I've probably caused at least as much confusion.

Steve
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Discussing M3 SMG pump reconditioning in the E46 M3 (2001-2006) Forum - Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006. at BMW M3 Forum.com (E30 M3 | E36 M3 | E46 M3 | E92 M3 | F80/X)