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Thread: SULEV conversion

  1. #1
    Join Date
    Apr 2017
    Location
    Texas
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    14
    My Cars
    2003 540i and 2003 530i

    SULEV conversion

    Picked up an 04 325ci m56 recently with a bad fuel pump. See previous post:

    The notorious M56 SULEV... fml
    https://r.tapatalk.com/shareLink/top...ink_source=app

    I will be working to convert the fuel system from a SULEV to a non-SULEV version.

    I tried looking up how to do this but could only find articles on how to replace the metal tank since the pump is built into the tank and the whole tank must be replaced to replace the fuel pump. I thought I would start a thread in case this can potentially help other SULEV owners in the future.

    I have a regular non-SULEV e46 I’m parting out so I will use the parts from this donor for the project.

    Pics and updates to come


    Sent from my iPhone using Tapatalk
    Last edited by HyptisX; 12-24-2019 at 03:34 PM.

  2. #2
    Join Date
    Mar 2016
    Location
    Portland, OR
    Posts
    712
    My Cars
    2002 325Ci Cabriolet

  3. #3
    Join Date
    Jun 2012
    Location
    New Mexico
    Posts
    915
    My Cars
    2003 328i
    It seems entirely possible to swap in a standard fuel tank and splice wiring and fuel lines. You may experience problems with the electronic aspect though. The fuel pump just needs 12 volts to run but the extent which the DME is involved with every single thing in these cars may cause problems. Fuel level senders may be a pain in the ass too.

    Seems worth a try though.

  4. #4
    Join Date
    Jan 2016
    Location
    Ca
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    6,981
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    2001 525it
    Sounds like a pain in the ass

  5. #5
    Join Date
    Apr 2017
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    Texas
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    My Cars
    2003 540i and 2003 530i
    A big pain in the ass now for less pain later..


    Sent from my iPhone using Tapatalk

  6. #6
    Join Date
    Apr 2017
    Location
    Texas
    Posts
    14
    My Cars
    2003 540i and 2003 530i

    SULEV conversion

    Conversion is done. Pics to come this week. It was a gaint PITA to source all the parts (since I didn’t want to reuse old gaskets from my donor) but worth it at the end. Still waiting for my last gasket for the driver side sending unit to come in but it runs and starts now!
    Last edited by HyptisX; 12-24-2019 at 03:36 PM.

  7. #7
    Join Date
    Mar 2016
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    Portland, OR
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    712
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    2002 325Ci Cabriolet
    Quote Originally Posted by HyptisX View Post
    Conversion is done. Pics to come this week. It was a gaint PITA to source all the parts but worth it at the end. Still waiting for my last gasket for the driver side sending unit to come in but it runs and starts now!
    How much did you spend?

  8. #8
    Join Date
    Apr 2017
    Location
    Texas
    Posts
    14
    My Cars
    2003 540i and 2003 530i

    SULEV conversion

    $30 for a plastic tank
    $45 for drivers side sending unit
    $25 for fuel pump assembly
    $10 sending unit gasket
    $20 parts from salvage yard
    $20 for hose adapters/clamps

    $120 total

    UPDATE:
    $20 340 LPH fuel pump made of Chinesium (courtesy of eBay)

    Sent from my iPhone using Tapatalk
    Last edited by HyptisX; 12-24-2019 at 03:38 PM.

  9. #9
    Join Date
    Apr 2017
    Location
    Texas
    Posts
    14
    My Cars
    2003 540i and 2003 530i

    SULEV conversion

    While the retrofit worked, there’s still some issues. The default fuel pressure for a SULEV is 5 bar vs regular is a 3 bar. I’m noticing the difference in responsiveness.

    Going to look into using a m3 pump as a alternative.


    Sent from my iPhone using Tapatalk

    Here’s the plastic tank before it went in.
    Last edited by HyptisX; 12-24-2019 at 03:30 PM.

  10. #10
    Join Date
    Apr 2017
    Location
    Texas
    Posts
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    My Cars
    2003 540i and 2003 530i

    SULEV conversion

    Got a 340LPH fuel pump and popped it right in. This worked! No more lean conditions on acceleration and response time is back to normal.

    Here’s a pic of the messy rewiring. Going to clean it up now that it’s confirmed working!


    Sent from my iPhone using Tapatalk

    Last edited by HyptisX; 12-24-2019 at 02:38 PM.

  11. #11
    Join Date
    Apr 2013
    Location
    Mill Valley, CA
    Posts
    346
    My Cars
    2003 330cic
    Did you have to do coding?

  12. #12
    Join Date
    Apr 2017
    Location
    Texas
    Posts
    14
    My Cars
    2003 540i and 2003 530i
    No


    Sent from my iPhone using Tapatalk

  13. #13
    Join Date
    Apr 2013
    Location
    Mill Valley, CA
    Posts
    346
    My Cars
    2003 330cic
    I have a donor 325i, and I am wondering if it would make sense to swap out the M56 intake for the M54 and use standard injectors - think that would work?

  14. #14
    Join Date
    Aug 2020
    Location
    Ventura, California, USA
    Posts
    4
    My Cars
    2004 325i wagon M56
    HyptisX
    It's great to see that you were successful with the tank swap on your M56. I've been researching this for a while based on the fact that with 134K on the clock, my 2004 325i wagon will eventually be needing the swap. Do you have more details of your process and a parts list so all of us M56 suckers can benefit from your experience?
    It would be greatly appreciated! Thanks,
    Wardto

  15. #15
    Join Date
    Jul 2020
    Location
    Gold Bar, WA
    Posts
    1
    My Cars
    1994 325is
    I'm just finishing up my M54B30/5-Speed swap into a SULEV. I swapped out the entire fuel system and emissions stuff. The only thing left is to re-wire the fuel tank harness. What M56 wires did you connect to the M54 fuel tank harness?

  16. #16
    Join Date
    Dec 2020
    Location
    Lebanon
    Posts
    1
    My Cars
    Bmw e46
    Hi can u help with what are the parts that need to be changed other than the tank

  17. #17
    Join Date
    Apr 2013
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    Mill Valley, CA
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    2003 330cic
    OP appears to be gone

  18. #18
    Join Date
    Nov 2006
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    Oxnard (Ventura), CA
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    99528it 02525it 04325it
    It has been a month and one week since he last logged in. Perhaps he’s too busy enjoying his ride after his accomplishment. I myself wanted to do this because SULEV are just going to the boneyards here in SoCal. I just want to make sure before I jump in into this project. They’re so cheap nobody wants them. Merry Christmas!

  19. #19
    Join Date
    Apr 2017
    Location
    Texas
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    2003 540i and 2003 530i
    Quote Originally Posted by easymoney View Post
    It has been a month and one week since he last logged in. Perhaps he’s too busy enjoying his ride after his accomplishment. I myself wanted to do this because SULEV are just going to the boneyards here in SoCal. I just want to make sure before I jump in into this project. They’re so cheap nobody wants them. Merry Christmas!
    Happy New Years y’all!

    I’m here in TX but I doubt you’ll pass CA emissions tests modifying all this (fuel system). The car isn’t perfect, I notice it would choke a little at startup when on a incline so still working out the kinks


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  20. #20
    Join Date
    Aug 2020
    Location
    Ventura, California, USA
    Posts
    4
    My Cars
    2004 325i wagon M56
    Hello HyptisX
    Please let us know what kinks are still giving you trouble...
    Thanks

  21. #21
    Join Date
    Apr 2010
    Location
    Phx, AZ
    Posts
    11
    My Cars
    1999 323i BMW
    Which fuel pump did you use? I have read that the M3 pump is the preferred one as it is a 5-bar pump and the 325 is a 3-bar pump...the hiccups may be related to poor fuel pressure under certain conditions?


    Quote Originally Posted by Wardto View Post
    Hello HyptisX
    Please let us know what kinks are still giving you trouble...
    Thanks

  22. #22
    Join Date
    Apr 2013
    Location
    Mill Valley, CA
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    2003 330cic
    Got inspired by your swap and did it on my wagon. I decided to use the whole m54 fuel system including injectors and rails. It starts and runs. No codes.

  23. #23
    Join Date
    Apr 2013
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    Mill Valley, CA
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    2003 330cic
    Quote Originally Posted by harrier View Post
    I swapped the whole m54 fuel system including injectors and rails. It starts and runs. No codes.
    I have a PDF guide with the instructions and parts list.

    Preview:
    Screen Shot 2022-10-31 at 10.34.50 AM.jpg
    Last edited by harrier; 03-18-2024 at 02:39 PM. Reason: broken link

  24. #24
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    Apr 2013
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    2003 330cic
    Quote Originally Posted by harrier View Post
    Did you have to do coding?
    Quote Originally Posted by HyptisX View Post
    No
    Sent from my iPhone using Tapatalk
    You definitely need to do coding, at least for the fuel tank level. It is not as simple as just swapping the tank and the pump by any stretch of the imagination. I am not sure how the OP hodge-podged together the connection from the tank to the filter and regulator to the fuel rail, but it is not plug and play. If you decide to go with 3bar pump and standard injectors you will need to do coding for that as well.

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