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Old Fri, Mar-07-2014, 05:11:39 PM   #1
wsl
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Default WSL 2002 M3 Journal

I've owned my 2002 steel grey M3 since July, 2008 but since it was my daily driver for the past 6 years I've only completed routine maintenance or minor upgrades. I decided to start a journal for my own record keeping and document more performance oriented upgrades. I sold my SpecE30 last May and was able to pick up a 2000 Touring with a 5 speed and sport package that has transitioned into my daily driver. The M3 will be used for track days while still being a street legal option. After building the E30 I found out I'm not a race car driver. I don't have the aggression needed and prefer track days and HPDE.



Maintenance items performed:

September 2008
Partnumber: 13721730946
Air filter 1
Partnumber: 11427833769
Oil filter 2
Partnumber: 83222282583
DIFF. OIL 1
Partnumber: 83220309031
GEARBOX OIL 1
Partnumber: 13327831089
Fuel filter 1
Partnumber: 61316902175
Window switch 1
Partnumber: 07510009420
OIL 10W60 12
Partnumber: 82141467704
ANTIFREEZE 2

January 2009
Partnumber: 83222282583
OEM BMW Rear Axle Fluid 2
Accessory Catalog
Partnumber: 82550151192
OEM BMW E46 All-Weather Front Rubber Floor Mats (Set of 2)
Partnumber: 64319071935
Cabin Filter 1

March 2009
Partnumber: 51138244714
Truck Release Handle 1

July 2009
Partnumber: PKE46M3VALVEKIT*
Valve Adjustment Kit 1
Partnumber: 07510009420*
OEM BMW TWS Motorsport 10w60 Synthetic Motor Oil 2
Partnumber: 11127831271
Engine - Cylinder head & valves - Inner gasket Inner gasket
Partnumber: 11127832034
Engine - Cylinder head & valves - Valve cover gasket Valve cover gasket
Partnumber: 11121437395
Valve cover - Bushing Bushing 2
Partnumber: 11127830972
RUBBER SEAL 13
Partnumber: 07119963129
RING 2

August 2009
Partnumber: 18111723379
Inner 1
Partnumber: 18307830674
GASKET 2
Partnumber: 11627830668
GASKETRING

November 2009
Partnumber: PKE46M3OIL
OEM BMW E46 M3 Oil Change Kit
Partnumber: 11347832285
ADJUSTING PLATE 6
Partnumber: 11347832286
ADJUSTING PLATE 2
Partnumber: 11347832287
ADJUSTING PLATE

September 2010
Partnumber: 25117527253
SHIFT LEVER 1
Partnumber: 25117519669
BUSH BEARING 1
Partnumber: 11347832284
ADJUSTING PLATE 4
Partnumber: 11347832285
ADJUSTING PLATE 1
Partnumber: 11347832288
ADJUSTING PLATE 1
Partnumber: 11347832287
ADJUSTING PLATE

April 2011
Partnumber: PKE46M3OIL
OEM BMW E46 M3 Oil Change Kit 1
Partnumber: PKS54vANOS1*
OEM BMW E46 M3 Vanos Filter Kit 1
Partnumber: 11347832284
ADJUSTING PLATE

January 2012
Partnumber: PKE46M3VCOVER*
OEM BMW E46 M3 Valve Cover Gasket Set 1
Partnumber: 11367831906
SEALING PLATE 1
Partnumber: 13627796054
Camshaft position sensor, m3 2002 - 2003 1
Partnumber: 07119963129
RING

May 2012
Partnumber: 07119904550
SCREW 5
Partnumber: 07119963151
Engine Engine parts Drain plug Gasket Gasket 10
Partnumber: 11347832284
ADJUSTING PLATE 1
Partnumber: 11347832285
ADJUSTING PLATE 6
Partnumber: 11347832286
ADJUSTING PLATE 1
Partnumber: 11347832287
ADJUSTING PLATE
Front rotors
Rear rotors
Ignition Coils 6

August 2012
Partnumber: 51217011250
body hardware, door, lock & hardware, lock assy Right 1

February 2013
Partnumber: 34111157037
brakes, hydraulic system, front brakes, caliper overhaul kit M3
31222229501 - Front Wheel Hub/Bearing Assembly 2
Includes bearing and ABS ring (83mm)

November 2013
Partnumber: 11727505259
emission system, a.i.r. system, valve gasket Z4 3.2L
Partnumber: 18307830674
exhaust system, exhaust components, intermed pipe gasket 3.2 LITER, 2001-02 Left 2
Partnumber: 07119902901
HEX BOLT 6
Partnumber: 11621744323
HEX NUT 6
Partnumber: 18301317898
HEX NUT M10

December 2013
Partnumber: 26122282495
universals & rear axle, rear axle, propeller shaft, center bearing
Partnumber: 07129900047
NUT M12X1.5 6
Partnumber: 26117526611
CENTERING SLEEVE 1
Partnumber: 23001222891
Diff BOLT 2
Partnumber:
Diff Bolt 1 $15.20
Partnumber: 26117540778
COVER 1
Partnumber: 26111229503
WASHER GASKET 1
Partnumber: 26111225017
CIRCLIP 1
Partnumber: 11621741172
NUT 4
Partnumber: 07119904533
HEX BOLT 4
OEM Catalog
Partnumber: 33326775551
BALL JOINT 4
OEM Catalog
Partnumber: 33326760668
HEXT NUT W/FLANGE 2
Partnumber: 33326770824
RUBBER MOUNTING 2
Partnumber: 33321092247
RUBBER BRG.
33411090505KT - Rear Wheel Bearing Kit ES#2586866 2
Contains wheel bearing, axle nut and circlip

January 2014
Partnumber: 16117176011
fuel system, fuel system components, hose 1
Partnumber: 07129952104
cooling system, cooling, hoses & pipes, vent pipe clamp W/O M6, RADIATOR 2
Partnumber: 16121180240
HOSE CLAMP 2
Partnumber: 07129952119
CLAMP/SPEC


Last edited by wsl; Wed, Apr-06-2016 at 11:11:05 AM.
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Old Fri, Mar-07-2014, 05:12:12 PM   #2
wsl
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Default Re: WSL 2002 M3 Journal



Upgrades/Performance

Options
-2002 Steel Grey
-6mt
-Premium Package
-Cold weather package
-Bi Xenons
-HK audio

Suspension
-KW V2 coilovers
-Turner Motorsport camber plates
-PowerFlex FCAB
-AKG subframe bushings
-AKG diff bushings
-AKG RTAB
-RE trans mounts
-RE rear shock mounts
-Alignment (F)-2.4, 1/16" Out (R)-2.0, 1/8" In

Brakes
-Alcon Monobloc 6 Piston calipers
-Dinan/Alcon 365mmx32mm 2-piece rotors
-Hawk DTC-60 pads (track)
-Hawk HB122 pads (street)
-Goodridge brake lines
-Stoptech street performance street pads
-Stoptech brake lines
-ATE Super Blue brake fluid
-Backing plates removed
-Brake duct cover removed

Wheels/Tires
-18” VRM V703 8.5"F 9.5"R
-Hankook Ventus V12 F-225/45 R-275/35
-18x9.5 ET33 APEX PS-7
-Nitto NT05 265/35
-Turner Motorsport 75mm stud kit
-H&R 10mm front spacers
-949 Aluminum valve stems

Lighting
-Lightwerkz TSX projectors
-55w, 4300k bulbs
-Depo corner lights
-Depo side marker lights
-Fog light delete

Cosmetic
-CF CSL style diffuser
-Matte black kidney grills
-Matte black side gills
-Alcantara shifter boot
-Alcantara brake book
-3M wrapped trim
-painted reflectors
-"M3" delete
-Color matched mirror covers
-Mirror John replacement wing mirrors

Interior
-Cobra Evolution Seats
-Bimmerworld floor mounts
-VAC Seat mounts
-Modified Bimmerworld roll bar
-Rear seat delete panels
-MOMO steering wheel hub
-OMP WRC steering wheel
-Rogue Engineering Quick Release
-Air bags removed

Exhaust
-CPI stepped headers
-CPI Euro 400 cell Sec 1
-Custom 3" 304 stainless exhaust
-Vibrant Performance Ultra-Quiet Resonator 1142
-Borla 40943 XR-1 SS Muffler
-Flowmaster tip

Tuning
-Tuning Tech Tune in-house dyno tune
-SMG shift lights turned on
-Cold start sequence disabled
-Sport mode memory enabled
-EGT tuned for headers
-Dyno mode enabled

Reinforcement
-Custom (REDDISH based) subframe reinforcement
-Custom reinforced rear subframe mounts
-Custom rear chassis support bar
-Custom front strut tower bar
-Custom rear shock mount reinforcement plates
-Custom OEM camber arm reinforcement
-Updated BMW diff mount bolts

Aero
-Custom front splitter
-SneedSpeed 63" CF wing
-Custom removable wing stands

Miscellaneous
-CDV delete
-DIY clutch stop
-RE stainless clutch line
-Engine cover delete
-Viton Fluoroelastomer high-temperature CPV o-ring


Last edited by wsl; Wed, Jun-29-2016 at 11:23:32 AM.
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Old Fri, Mar-07-2014, 05:12:38 PM   #3
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Default Re: WSL 2002 M3 Journal

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Last edited by wsl; Fri, Mar-07-2014 at 06:03:13 PM.
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Old Fri, Mar-07-2014, 05:13:01 PM   #4
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Default Re: WSL 2002 M3 Journal

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Old Fri, Mar-07-2014, 06:12:45 PM   #5
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Default Extending O2 wiring for Section 1 with Cats

From this Thread

While I'm waiting for my stepped headers I decided to extend the factory O2 sensor wiring to accommodate the Section 1 with cats. You do not need to cut any wires to extend the O2 fittings, only removed them from the factory loom. Searching found plenty of information describing what to do, although not many images. Based on previous threads, I bought the euro wire routing plastic:



14 GUIDE RAIL 1 11787831183
15 GUIDE RAIL 1 11787831182

I thought finding the mounting location would be obvious. I held the O2 sensors in the approximate location and ran the wires around the driver side of the transmission tunnel. The leads almost reach the firewall so I was looking to install the euro plastic near the fuel filter. I doesn't go there, it mounts here:





While this location uses the factory mounting holes, it had two problems for me. First, it is exposed. I couldn't confirm it, but it appeared the connectors would be the lowest part of the car when installed in the mount. Second, I couldn't get the wires to reach the mount. This is the best I could do:





I already had the exhaust out so my wiring harness was already out. I removed the O2 and EGT wiring from the grommet located on the rear intake side of the valve cover by cutting the rubber. I also cut the OEM O2 loom back to where it meets the large rubber boot beside the brake booster.





I removed the vacuum line on the rear of the intake to allow more room for pulling the O2 wiring loom over to the driver side. I also ended up removing the cover/shield beside the brake booster in order to access the OEM loom. I put a new loom over the separated post cat wires and ran them down the firewall beside the transmission sensor wiring.



I'm waiting until I install the new exhaust before sealing the loom and fitting it securely to the vehicle. Working under the car I found a few studs that may work for mounting the OEM euro mount. With all these options, nothing really lined up with the OEM mount.



I modified the bracket by removing one mounting tab and the 90 deg bend. I used two of the upper studs and made a small metal bracket that slipped over the plastic bracket to hold it tight to the tunnel. The other mounting point uses an OEM cable fitting.



The O2 wiring is held in place with other OEM wire holders located along the driver side tunnel. I will secure the remainder of the wiring after the exhaust is installed and I can verify the location works with the sensors.



I did not cut any wires, I only extended the OEM O2 wires that are located under the engine cover and enclosed in the factory looms.

The OEM O2 wires use different looms to go from the engine to the area behind the brake booster. They start in the hard plastic corrugated loom, through a soft rubber boot, into a hard plastic cover and finally through a soft rubber corrugated boot.





I only cut the hard plastic corrugated loom back to the soft rubber boot. I tried locating the loom with the hard plastic cover behind the brake booster but this still did not provide enough length for the wires to reach the euro bracket.

Quote:
Originally Posted by bmwbob View Post
also what kind of small bracket did you make? i cant see it in the pictures.. can you picture it so i can make my own?
I removed one of the mounting tabs and the 90 deg bend from the euro mount. I kept the straight part of the 90 deg bend since I purchased the cover and needed to use the two mounting tabs to attach it.



The bracket is just a piece or scrap metal bent to slide over the bracket and reach one of the existing studs on the transmission tunnel. I looked at attaching something to the mount but I didn't want any fasteners to get in the way of securing the O2 wiring. After a coat of primer I used a spare 'nut' to attach it.





Installed:

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Old Fri, Mar-07-2014, 06:14:47 PM   #6
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Default Subframe reinforcement

From this Thread

After 100k+ miles I thought a fun winter project would be to refresh my rear suspension bushings and reinforce the mounting points. I used the Redish Motorsport plates as a start, ended up making some adjustments in shape and went with a slightly thicker metal. The work was completed over several weeks since this is the first year the M is not my DD. I found no signs of failure or cracks in the body, car is 2002.



I ended up replacing all moving bushings with OEM. Subframe, diff and RTAB are by AKG. Installed Rogue trans mounts and SS clutch line while I was under the car. I also modified the camber arms, similar to the reinforcement kit available by Turner.

The final part was making front and rear strut bars to help stiffen the chassis. I have been working on these for some time, just needed to finish the subframe mounts before installing. I used the Mason Engineering instructions for their rear bar as a guide, and modified the mounts/floor to mount the bar.

I drilled through the floor from under the car, tapped the remaining whole, welded the top of the opening and added a 1/8" plate to the floor before setting the bar. The top closure plate is cosmetic.

Getting started:

Inspecting mounts:





New plates added, undercoated:







Front/Rear strut bars:

Detail of rear bar:



Floor reinforcement:

Floor mounts:

Closure plate:

Rear bar:

Front bar:


UPDATE

While waiting for some exhaust parts to arrive I decided to strengthen the front strut bar I built over the winter. I decided to add a second bar and follow with smaller intermediate bars similar to the Mason bar.



After I tacked in the new bar, it started to get heavy. I decided to try and make plates like used to connect roll cages to A/B pillars.



Over to the press. I used some scrap sheet metal I had, found a hole saw and some scrap pipe that looked like a good match a gave it a shot. I had to taper the end of the pipe to fit the hole and used an old bearing race under the plate.











I'm sure you can buy these plates pre-made, after figuring out what size pipe/hole to use it was an easy project.

Last edited by wsl; Mon, Mar-10-2014 at 01:15:01 PM.
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Old Fri, Mar-07-2014, 06:17:58 PM   #7
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Default Valve adjustment worksheet



PM me for high res if needed.
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Old Fri, Mar-07-2014, 08:40:40 PM   #8
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Default Re: WSL 2002 M3 Journal

Awesome car! Could you please post more pictures of your car when it had the gunmetal wheels on it? Much appreciated and look forward to more updates.
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Old Mon, Mar-10-2014, 01:28:03 PM   #9
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Default CPI Euro 200 Section 1

I received the first part of my exhaust from CPI, I section 1 with 200 series catalytic converters. I was part of the first group buy for the CPI stepped header these will be bolted to. More on those when they arrive. I debated on making a section 1 but I don't have access to a mandrel bending machine and the CPI sec 1 was a good value when combined with the header group buy.

The part arrived in a sturdy box and a layer of bubble wrap. There was a tear or two on the outside but nothing penetrated the box. The part fit well in the box, nothing to move around.



I was surprised to see that hardware included, not sure if this was advertised on not. I now have new OEM gaskets, sealing rings and hardware if/when I decide to put the factory stuff back on.



I know TIG welding takes more time and effort than traditional MIG welding and I don't know that I would care if both type weren't on the same part. This just makes a quality part look poor in my opinion.



I can't comment on fitment since this will be used on the CPI stepped headers and a custom 3" exhaust. The part is well made and in an official comparison may even weight less than the OE version.
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Old Mon, Mar-10-2014, 02:42:51 PM   #10
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Default 3" exhuast

After upgrading to CPI stepped headers with a catted section 1 I decided to make a custom 'cat back' system similar to the Bimmerworld Street/Track setup. At $824 plus shipping, the BW system appeared to be a good solution. I wanted to reduce weight, be affordable, single pipe and not lose HP or TQ.


Image from gotbhp? on E46F

After reading reviews, watching videos and taking a ride in a local car I thought the increase in NVH would be too much for me. It's still a street car and the drone of the street/track version would wear on me. I thought about adding a resonator to the BW system to bring the noise down, but this would add cost and require modification. Why not just build my own?

I'm told size matters so I did the usual internet research to find the right diameter pipe for my exhaust. After reading about exhaust flow, velocity rates and other topics engineers like discussing I settled on 3".


Rouge Engineering Midpipe - 76mm (~3")


Custom Performance Inovations Midpipe - 3.25"


Supersprint Midpipe - ??.?"

With prices ranging from around $400 to $800 for just a midpipe, my goal was to build a complete cat back stainless 3" exhaust system for the less than $500.

After studying some images of the BW system installed, I ordered 8' of 3.00" x .065" 304 stainless straight pipe and 2 30-deg mandrel elbows to get started. I wanted the exhaust to exit in the left opening of the OE diffuser. In order to accomplish this, a 12" long muffler appears to be the largest size that will fit. After more expert research on Google, I decided on Borla XR-1 series oval muffler for the rear section and an inline Vibrant Ultra Quiet resonator after section 1.

Setting the 3" in place to check for clearance:


Expensive stainless is expensive:


Elbow room:


I plan to use the OE rubber mount located at the front of the section 2, but needed a way to support the back. Since I am nervous about making sure the muffler is in the center of the opening, my mounting system may be a little overkill. I made brackets that use the studs for the OE muffler mounts to support a cross bar that will carry two rubber muffler mounts. I am using a series of zip-ties to position the muffler as I cut/bend/bang the tubing to reach the front of the car.

Driver's side bracket:


In position:


With diffuser:


Clearance at sway bar mount:


I used 1/2" wood blocking around the muffler and suspension to maintain clearances. More info to follow, I'm waiting for stainless bar to make the hangers for the muffler and for the stepped headers to arrive so I can locate section 1 and fabricate the transition to 3" tubing.

Stay tuned.

Last edited by wsl; Mon, Mar-10-2014 at 05:57:06 PM.
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Discussing Radek's Build Jorunal in the Member Journals Forum - Do you have a long term project you would like to share with the community? Use this forum to create a single thread which you can update over time to document the progress. at BMW M3 Forum.com (E30 M3 | E36 M3 | E46 M3 | E92 M3 | F80/X)