Hello,I'm documenting an undergoing project to convert my 2002 E46 318i N42 CKD from auto to manual.HistorySince 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 anybodyReferenceshttp://forum.e46fanatics.com/showthread.php?t=659314http://forum.e46fanatics.com/showthread.php?t=396320http://forum.e46fanatics.com/showthread.php?t=855303http://forum.e46fanatics.com/showthread.php?t=889867Knocking from underneath the car[video=youtube;PLO9QaZ00oc]http-~~-//www.youtube.com/watch?v=PLO9QaZ00oc[/video]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 12:07:56ECU: GS20JobStatus: OKAYVariant: GS20-------------------------------------------------------------RESULT: 2 errors in error memory !-------------------------------------------------------------146 CAN Moment interfaceError frequency : 2Logistic counter: 16Error occured 1. times at:km value 135600.00 kmChanging gear 1.00 0/1Last change: implausible 76.00 0-nEngine speed 832.00 rpmThrottle-valve angle 0.00 %Error occured 2. times at:km value 135600.00 kmChanging gear 1.00 0/1Last change: implausible 76.00 0-nEngine speed 864.00 rpmThrottle-valve angle 0.00 %General errorSporadic error-------------------------------------------------------------48 Torque Converter Clutch - too much slipError frequency : 6Logistic counter: 5Error occured 1. times at:km value 137030.00 kmGear 160.00 -Gearbox Oil Temperature 111.00 degrees CSV 1 0.00 0/1SV 2 0.00 0/1SV 3 0.00 0/1TC-clutch closed 1.00 0/1SV Shift-Lock 0.00 0/1Brake operated 0.00 0/1Error occured 2. times at:km value 137070.00 kmGear 160.00 -Gearbox Oil Temperature 108.00 degrees CSV 1 0.00 0/1SV 2 0.00 0/1SV 3 0.00 0/1TC-clutch closed 1.00 0/1SV Shift-Lock 0.00 0/1Brake operated 0.00 0/1Error occured 3. times at:km value 137430.00 kmGear 160.00 -Gearbox Oil Temperature 101.00 degrees CSV 1 0.00 0/1SV 2 0.00 0/1SV 3 0.00 0/1TC-clutch closed 1.00 0/1SV Shift-Lock 0.00 0/1Brake operated 0.00 0/1Blocked openSporadic error============================================================= Car has been resting well..Parts at its origin locationParts here - drive shafttransmissionother stuff and clutch lineunwrappedknobshifterdmf flywheel and sac clutch setpedaltransmission supporthttp://i791.photobucket.com/albums/yy197/aidilj/manual%20conversion/DSC03793.jpgexhaust support and boothttp://i791.photobucket.com/albums/yy197/aidilj/manual%20conversion/DSC03794.jpgGetrag 220http://i791.photobucket.com/albums/yy197/aidilj/manual%20conversion/DSC03800.jpgManual trans fluid is also for lifehttp://i791.photobucket.com/albums/yy197/aidilj/manual%20conversion/DSC03801.jpgfriction plate doesn't have much life lefthttp://i791.photobucket.com/albums/yy197/aidilj/manual%20conversion/DSC03830.jpgRelease bearing renewed with sachs replacement acquired from Ban Huat Chanhttp://i791.photobucket.com/albums/yy197/aidilj/manual%20conversion/DSC03832.jpghttp://i791.photobucket.com/albums/yy197/aidilj/manual%20conversion/DSC03833.jpgaround the househttp://i791.photobucket.com/albums/yy197/aidilj/manual%20conversion/DSC03836.jpg
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/foru...gh-and-available-parameters-2002-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 [HR][/HR] 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
Until now, I've spent less than rm3k for parts and shipping but since I used surface shipping (by boat), waiting is boresome. Almost gave up waiting.. Hopefully a DIY, I'll be consulting an experienced mechanic for advice and help on this. Not forgetting a facility with all the right tools. Bro thanks for the kind words. Hopefully this is a success. I would sure hope so, and hope this thread would show them whats involved in the process You are the one to be blamed for that..!! :evil: thanks bro
Wahhhh ... interesting project indeed! Thank you for sharing and documenting it :adore: All the best bro :top: Dear mods please sticky this thread :4:
