Daily Build Project: 2003 E46 325ci

[Jive_E46]

Watkine ous,

Sold my F20 M135i and went for something abit more reasonable, a platform that I could still express my love for a real BMW but also use something abit more reliable and better on petrol. I've always had a thing for the E36 and E46 so my affliction for this Ci is only natural. I had a budget and decided not to limit the build to the book value of the car and all that crap, I will build this car exactly how I would want it- the Euro stance look.

This is a Silver-Grey Metallic finish with the sports pack, Harmon/Kardon sound as standard. 180 000 KM on the clock

Stan and Rodz got the car back to relatively good health so big ups to them for working on my golden oldie, but still a couple of oil leaks to sort out lol. Parts changed:
1. Sump gasket(still looks like its leaking)
2. Valve cover gasket
3. Valve cover
4. Oil filter gasket+ oil filter
5. Return line for CCV/PCV system
6. Powerflex Control arm bushing
*still need to find one more oil leak
Running Shell fully Synthetic

The M54 motor is pretty bulletproof, it just doesn't make any power especially with the 2.5L crank BUT nonetheless I would still like to improve the power band per gear while utilising the DISA flap and improved VANOS software. After this I'd like to source a 2.8L crank. I'm well aware of the fact that these chassis crack easily so I will definitely look into reinforcing the chassis for the long run. I truly believe this process has to be methodical so I will be refreshing all the bushings with Meyle HD or Powerflex Street bushings (polyutherane might just put extra stress on the chassis itself ) when the coilovers come in Ultra-racing front and rear strut braces should be okay for now but would definitely like to do some welding reinforcements.

As for the exterior I've gone for OEM BMW Style 224M(Z4M) 8J and 9J rims wrapped with Michelins Pilot Sport 4 225 and 255(I know, tyre overkill), waiting for a gap during the week to fit the M3 bumper. Irshaad from See-dat Motorstyle helped me out alot. Still a few more exterior bits to add. I couldn't believe E46 M3 mirrors are going for R5k second hand, I was shook.

Just got it back recently from Viper Exhaust and super happy with the sound and cabin noise-- my ears have finally earned a well deserved break from that filthy 86mm pipe on the F20. Dual 50mm pipes into Box1 then 76mm pipe into box 2 dual pipe offset look.

Gonna continue this build thread with maintenance updates and upgrades. If anyone has any advice or information please share it here, it will be truly appreciated. Contacts for the chassis reinforcements is desperately needed( around the subframe bolt on areas as well as the shock mount areas ) especially with the way I drive.

Overall I'm extremely happy with this ride, I've always wanted an E46 and can confidently say this was no compromise, excited to join the 3er fraternity!

Next step:
Meyle HD bushings refresh
Tunetech MS43 software

PS: Should I do the engine mounts ?

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[KPM3_30]

Welcome to the E46 club.. Owning and maintaining these cars are a labour of love, given the age of them. I've owned mine for just over 6 years, have a look at my thread for some of the things I've done over the course of the years.

Glad you came right with the exhaust from Viper, would love to hear how it sounds. Wishing you many miles of smiles :thumbs:

 

[Chrism135i]

Congrats sad to see you leave the 35/40s but CI is tops. Air it and faga some Rotis

 

[Spanky]

Big moves! Good luck with the build - will be following along keenly.

 

[Riaad]

Nice to see another 46 rocking style 224s raise:

will be watching this build, can i suggest maybe going for the m-tech 2 front bumper instead of the m3? for me, without m3 fenders...the front bumper looks out of place.

Just my 2c...All the best bud!

Also, 9Js at the rear...you must be rubbing alot :fencelook:

 

[individj]

lovely...i actually like the M3 bumper and think its works...especially on a Ci which has bumpers without strips ...the Mtech kit for the Ci looks great too...lovely side sills...great looking rear bumper...well done on finding an aftermarket M3 bumper for a facelift Ci...very very hard to find.

 

[Jive_E46]

Nice to see another 46 rocking style 224s raise:

will be watching this build, can i suggest maybe going for the m-tech 2 front bumper instead of the m3? for me, without m3 fenders...the front bumper looks out of place.

Just my 2c...All the best bud!

Also, 9Js at the rear...you must be rubbing alot :fencelook:

Already have the bumper sprayed and everything, but I'll take a look at the fitment and make the decision on the M Tech kit, it doesn't really rub at all- the offset is perfect on these rims and the Michelins are just the right size, I havent really experienced bad roads but speed bumps etc is easy.

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[Blue Shirt]

The M54 motor is pretty bulletproof, it just doesn't make any power especially with the 2.5L crank BUT nonetheless I would still like to improve the power band per gear while utilising the DISA flap and improved VANOS software.

Do tell more about how this can be achieved?

Asking on behalf of other M54B25 owners.

 

[Jive_E46]

The M54 motor is pretty bulletproof, it just doesn't make any power especially with the 2.5L crank BUT nonetheless I would still like to improve the power band per gear while utilising the DISA flap and improved VANOS software.

Do tell more about how this can be achieved?

Asking on behalf of other M54B25 owners.

Sure thing, I'm going to look at the tuning side of things from a different perspective. We all know that N/A engines benefit from a good exhaust system to improve performance, from my couple of days of driving the car with the Viper system the car feels alot more responsive and slightly happier at the higher RPMs compared to that crap the previous owner did to this exhaust(cut and weld at a tyre shop mxm), Back pressure for N/A cars is super NB!! otherwise you'll just be losing power.
Next would be the intake and converting from the closed box intake to the cone intake(CAI) system similar to what K&N offer but all can be custom fabricated in SA, I definitely plan to test the long tube vs. Short tube designs for the intake pipe.
After the intake and zorst its time to crack the ECU, I've been reviewing the various software options and I'm going for the Tunetech setup as it offers ZHP VANOS maps, aggressive fuelling maps, custom crackle maps and basically everything is open to the tuner for adjustment. I understand Xcede also do MS43 software that have some good rep behind them too. I wouldn't go anywhere close to plug n plays.
Upgrade to Bosch Green Top injectors to help with fuel flow at high RPMs and as preventative maintenance too.
Camshafts: these will improve the power band in the higher RPM but low end torque may suffer, which is why I plan to retain the DISA flap. There are different options for a 264/248 cams- Schrick(If anyone can bring them in at a good price that would be awesome) or have the cams modified locally, I'm planning to do this to an extra set of cams for now. For a less aggressive cam setup the 248/248(intake/exhaust) as found on the 330ci ZHP should do the trick.
You're probably still gonna make around 140WKW max BUT it's not about the numbers with these M54B25- it's about power delivery

To get a definite jump in power throw in a 2.8L or 3.0L crankshaft then we talking numbers.

Having finally gotten the car back from the numerous shops I can say that I'm loving the 46 life!! The Arctic silver front bumper is driving me crazy but that will be swapped out soon.

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[Phat01]

Hey man. Congrats on the Ci and all the best with your future plans of modding it.

I used to see your M135i around the Centurion area and on a few occasions I got to see you blasting it here and there. Haha.

Will keep an eye out for this one one and will give you a hoot the next time!

 

[///M Individual]

Congrats and good luck with the build bud!

Subscribed to this one.

 

[Jive_E46]

Thanks for the kind words
Heres some soiled spark plugs and wet coilpacks, changed out the day I took ownership.
Powerflex control arm bushings done at SR Speedworx.
Viper system

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[Jive_E46]

Managed to get the bumper on still needs some alignment but that's for the weekend.
Still a few more body parts to go on. Excuse the dirty ride:

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[NAS325ci]

Looks good man

 

[individj]

that front end looks so damn hot!!!

 

[KingKalie]

Looks good, looks different :thumbs:

 

[leachieboy]

All the best with the wheels man. I saw her sitting at SR when I was there awesome ride.


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[Chucky]

Looks Good

You gotta do the rear bumper and skirts just my 2c

 

[Jive_E46]

Looks Good

You gotta do the rear bumper and skirts just my 2c

I dont see much of a design difference when it comes to the side skirt but the individual rear bumper is a must, but I'm sure it will look better with coilovers installed too. I did colour match the black plastic strip on the rear bumper so it doesn't look thaaaaat bad lol.

Getting to grips with the oil leaks on this car- The gaskets I've replaced so far:
1. Sump gasket
2. OFH gasket(top side- I think the bottom side gasket is torn)
3. Valve cover gasket
4. Replaced oil return lines.
Did I miss any gaskets or parts that are prone to failure ?

At what point does the leaking oil on the floor get bad? Currently getting a puddle when I leave it sitting for 3 days- When I have the time its going in to find all the oil leaks but for now these engines are bulletproof so I just check oil level and fill up when I drive her around.



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[individj]

individual side skirts are fantastic