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My E46 330d Touring Project
#1
octo 
Good evening BMW Fanatics, it has been a while since I have posted content on local forums. I have been keeping to myself and spending lots of time in the garage staying busy on various projects but thought it was time to return to fanatics with some content for you to peruse, this is my latest project and one I have been itching for quite sometime to build.

The Touring was a 2003 318i Auto with 162 000km, it belonged to my nephew who lives in George, Western Cape which is a little over 1000km from me. He had motor issues from day one and owned it for a little over a year until the engine blew a chunk out the block between cyl1 and 2. I bought it off him as a non runner after a George bmw mechanic stripped the head off exposing the damage to the block.
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Came with spare wheels

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Transported the 1000km to Johannesburg by a courier who deals in non runners.

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Arrived safely and in my garage awaiting its fate.
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Didn't take much time dropping out the engine/drivetrain remains.
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As a rolling shell I was able to do some pressure washing under the carport instead of the garage.
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Enter the donor car, 2003 330d manual 6spd
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Teardown
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Stripped out the interior for a few reasons, to access wires and to clean up the interior components piece-by-piece and transfer over to the green 330i sedan seen in some of the pics. At the same time I transferred the Harmon Kardon system and electric roller sunblind from the white 330d to the green 330i.
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The green 330i is looking fresh with the grey interior.
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Back to the 330d sedan, looking at the differences between the connectors where body harness meets engine management.
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Petrol vs Diesel connector
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The converting over, label everything!
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My garage is so full at the moment I cant park my daily's inside..
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Replacing shifter linkages and seal on gearbox while its out. Will do more maintenance while things are easy to access.
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White sedan body wiring successfully converted to 330i spec (which is what it will become)
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Now to convert the touring body harness to diesel which is where Im at as of today.
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A couple things I forgot to photograph was the rear subframe/suspension swap over and also the fuel tank/lines/filler neck swap over. The diesel uses a return style fuel system whereas the petrol uses a dead-head system, because of this the tank breather system was also different and needed swapping over too.

Wagon with diesel subframe and fuel tank.
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Forgot to take pics of the 3rd pedal and associated parts install but it involves removing the entire dash and HVAC system to install the hardline.
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For better interior access I put the front end on one of my home made shop dollies and rolled it away from the lift, very easy to move the car about the garage and turn it around so natural light can light up what you doing. I work completely alone so every job has to be a one man job and not back breaking.
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I got the green 330i's interior swap 99% finished yesterday, one or two little things to sort out and then time to find her a new home.
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Replaced the selector shaft seal and all the shifter components to freshen up the feel, added a shorter shifter at the same time.
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Deleted the EGR system
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Pulled the intake to install a swirl flap delete kit that I imported, unfortunately its the wrong size kit. Sad
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Swirl flaps are still in good shape nonetheless.
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Engine/drivetrain married to the wagon chassis. More sexy wagons in the background.
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Finished up the wiring, soldering connections, heat-shrinking joins ect. I also blanked off the EGR port on the exhaust manifold by cutting off the end of the pipe and tig welding in a blanking plug to close it off.

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First start video
https://youtu.be/K55S9lmPJlE

First start


Ebox looking factory again after tidying up the wiring chaos.
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DSC unit swapped from white sedan over to the touring and I did an extensive brake fluid flush of the whole system making sure there's no air bubbles or old fluid left behind. Clutch pedal feels great and brake pedal feels new again, success!
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Got the pdc wiring finished, pinned to the correct distribution blocks and fuse 24 installed ect. PDC working as factory and because canbus connected it can be diagnosed if faulty in future. Clutch switch wiring is also complete as well as the extra wire to the cluster plug.
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PDC gong had to be wired along with the system install.
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Last pic, my Main Coon and two moggies approve all the new upgrades. Wink
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All the interior is installed and that side of things complete. Engine bay area 99% complete, just have to insulation tape the harness on passenger side and get AC system a regas after lockdown. I took the car on its first drive to the shop and back, all feels solid and Im stoked about the turnout. The extra torque is exactly what the heavy touring body needs, Im sure this will give my white 330i touring a good run for its money, especially here in Johannesburg which is 6000ft above sea level.
Onto some pics:

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Couple with my other touring.

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#2
Good work as always Gizmo, keep it up Bravo
'13 E82 Coupe 135 - Weekend Toy
'03 Audi A4 2.0 - Daily
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#3
This is great work and a great achievement  Bravo 

Don't think there is another 330d Touring in any E series in SA.

Well done Gizmo Chef
Current Rides
2013 Audi Q7 3.0 V6 TDI S Line
2006 Audi A3 Sportsback 2.0T S-Tronic Ambition FRC ECU & S-TRONIC TUNED

(Ex BMW'S 2006 335i, 2006 X3 30d 2003 330i, 2002 325i 2000 540i, 1998 318i MS, 1992 325i MEX)
(NON BMW'S 2006 A4 AVANT, 2003 POLO 1.6, 2000 200 STI, 2000 RSI 20V, 1999 GTI, 1998 RSI 20V)
(1997 RSI 20V, 1997 MICROBUS, 1993 RSI T/C, 1992 GLI T/C, 1986 GLI T/C)
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#4
Nicely done there, I can see lots of man hours spent in those pics.

So which one is going to the next track day?
2011 E90 M3 M-DCT, Akrapovic Exhaust, more to come... Build thread here
2011 F25 X3 35i M-Sport, JB Stage 1, ex-Downpipe Build thread here
2007 E87 130i M-Sport: Alpine Upgrade, BMWP Intake, BMWP Exhaust Build thread here
2007 Corsa C Ute 2l 16v Tebbo Bluebiggrin : Build thread here
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#5
Woah amazing work done here!  Praise

Welcome back!
[Image: 330-white-sig_8660310438.png]

In garage
My 330 - 01 BMW E46 330i 5-speed manual
The other 330 - 02 BMW E46 330i 5-speed manual
95 Nissan 1400 bakkie
03 BMW E46 318i N42 Manual Sold
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#6
Awesome stuff man!

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(16-05-2020, 07:02 PM)YUBEN Wrote: This is great work and a great achievement  Bravo 

Don't think there is another 330d Touring in any E series in SA.

Well done Gizmo Chef
You'd be surprised... Wink

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#7
Great to hear from you again!! Great work done there!
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#8
Thank you all for the kind words. Will update this thread as the car develops. I have some cool and unique ideas I would like to try. The torque is so addictive, I want more haha!

Yuben, I know of one or two imported e46 330d tourings, both like an avus blue colour. They were both autos iirc.
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#9
Wonderful to see a thread from you again Gizmo, this is really something. What a build!
Current:
'14 F30 335i MSport Alpine White III, Coral Red, Sat Nav, iDrive touch, PDC + reverse cam, Harman Kardon, N55 230wkw | 477wnm Rogue Performance Downpipe
'16 F30 318i LCI Manual, Alpine White III, Black Leather
[Image: banner%20final_1261154562_8282635603.png]
[Image: m_fanatic2_8387882621.jpg]
Mods: Optic Blue Lamin-X fogs, VPS light shields, CF Splitters, Mirrors, Ducktail spoiler, Aluminium interior trim upgrades...

Retired BMWs:
'12 F30 320d
'12 F20 118i
'09 E90 LCI 320i M-Sport
'07 E90 320i Excl
'91 E30 325iS Evo I
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#10
nicely done   Bravo
530D Xcede s/w and down pipe
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#11
Awesome work, looking forward to more content.
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#12
Some of the options I added while building the car was factory PDC, electric seats and xenon headlights, I consider them "have to have" options and wired them into the body harness using factory wiring and fuse locations.
I would like to do mtech 2 front bumper and big aftermarket intercooler as they will be needed for the future power plans.
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#13
(17-05-2020, 06:03 PM)Gizmo Wrote: Thank you all for the kind words. Will update this thread as the car develops. I have some cool and unique ideas I would like to try. The torque is so addictive, I want more haha!

Yuben, I know of one or two imported e46 330d tourings, both like an avus blue colour. They were both autos iirc.
One was a topaz blau manual msport

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(17-05-2020, 06:29 PM)Gizmo Wrote: Some of the options I added while building the car was factory PDC, electric seats and xenon headlights, I consider them "have to have" options and wired them into the body harness using factory wiring and fuse locations.
I would like to do mtech 2 front bumper and big aftermarket intercooler as they will be needed for the future power plans.
I saw the green one also had xenons but I don't see any headlight washers - were xenons added as well?

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#14
(17-05-2020, 06:48 PM)rodga Wrote:
(17-05-2020, 06:03 PM)Gizmo Wrote: Thank you all for the kind words. Will update this thread as the car develops. I have some cool and unique ideas I would like to try. The torque is so addictive, I want more haha!

Yuben, I know of one or two imported e46 330d tourings, both like an avus blue colour. They were both autos iirc.
One was a topaz blau manual msport

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(17-05-2020, 06:29 PM)Gizmo Wrote: Some of the options I added while building the car was factory PDC, electric seats and xenon headlights, I consider them "have to have" options and wired them into the body harness using factory wiring and fuse locations.
I would like to do mtech 2 front bumper and big aftermarket intercooler as they will be needed for the future power plans.
I saw the green one also had xenons but I don't see any headlight washers - were xenons added as well?

Sent from my Redmi Note 8 using Tapatalk
The Topaz one, was it not auto and converted to manual 5spd? or was that the other blue one?

You are correct, I added factory xenons to the green 330i also, just waiting on a certain speed cop to come collect her... Fencelook

I enjoyed building this car so much I have already purchased another 330d 150kw sedan donor (accident damage) for the next touring to come my way.

I also have a e46 coupe project im busy with, it was a Japanese import 2000 318i auto which I have dumped the drivetrain, fitted M3 diff and rear suspension, converted to manual 6spd and building a fresh engine for it and throwing in a bunch of options along the way. It will have a high compression N/A M52 bored and stroked to 3.2lt using 330i crank and rods and Opel superboss pistons, im in the process of assembling the engine but I will do a separate thread for the coupe build.
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#15
Touring. Diesel. Gets my vote.

Nice build.

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#16
(17-05-2020, 07:08 PM)Gizmo Wrote:
(17-05-2020, 06:48 PM)rodga Wrote:
(17-05-2020, 06:03 PM)Gizmo Wrote: Thank you all for the kind words. Will update this thread as the car develops. I have some cool and unique ideas I would like to try. The torque is so addictive, I want more haha!

Yuben, I know of one or two imported e46 330d tourings, both like an avus blue colour. They were both autos iirc.
One was a topaz blau manual msport

Sent from my Redmi Note 8 using Tapatalk

(17-05-2020, 06:29 PM)Gizmo Wrote: Some of the options I added while building the car was factory PDC, electric seats and xenon headlights, I consider them "have to have" options and wired them into the body harness using factory wiring and fuse locations.
I would like to do mtech 2 front bumper and big aftermarket intercooler as they will be needed for the future power plans.
I saw the green one also had xenons but I don't see any headlight washers - were xenons added as well?

Sent from my Redmi Note 8 using Tapatalk
The Topaz one, was it not auto and converted to manual 5spd? or was that the other blue one?

You are correct, I added factory xenons to the green 330i also, just waiting on a certain speed cop to come collect her... Fencelook

I enjoyed building this car so much I have already purchased another 330d 150kw sedan donor (accident damage) for the next touring to come my way.

I also have a e46 coupe project im busy with, it was a Japanese import 2000 318i auto which I have dumped the drivetrain, fitted M3 diff and rear suspension, converted to manual 6spd and building a fresh engine for it and throwing in a bunch of options along the way. It will have a high compression N/A M52 bored and stroked to 3.2lt using 330i crank and rods and Opel superboss pistons, im in the process of assembling the engine but I will do a separate thread for the coupe build.
There is another topaz one but manual.

What is needed for the xenon retrofit besides the headlights?

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#17
I wire in a 4700uf capacitor to correct the cluster fault, no need to code the LKM in my case. Been working for me for 15years and I have used the same method on every car I have added Xenons to.
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#18
Great work Gizmo, perfect conversion matches too with the Tourings and the 330d powerplants!
Current:
2013 EB BMW M135i F20 - DP, K&N Filter, Xcede Stage 2 - 264wkw/635wnm
2016 Ice White Hyundai ix35 R2.0 CRDi Elite -
2008 Silverbird Grey VW Polo 1.4i Trendline

Gone but never forgotten:
2011 Mercedes-Benz C250 CDi BE Avantgarde - Madness Tuned
2010 Titanium Silver BMW 320d Exclusive E90 LCi - Chiplogic Tuned
2008 Stratosgrau Stratos Grey BMW 320i Individual E90
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#19
Brilliant conversion Gizmo. Great to see one of your build threads again!
2013 BMW 320d Manual - Glacier Silver
RK Motion

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#20
Thread of the month!
#NoLivesMatter
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