M54B30 rebuild and Swap to 2002 525i (flashed) completed

[mnewman]

I just can't get away from these cars. I sold my supercharged 2001 530i last year as I had my fun with it and it was time to move on. Shortly after I started peeking for E39 cars on craigslist. I found a really clean 2002 525i with head gasket issues for 800.00. I couldn't walk away from the deal. I ended up driving it for 2 months until it finally gave up the ghost. I had 2 M54B30's on stands, once of which is a ZHP. So I broke down the motor and got it off to the machine shop here in San Diego, CA. It only took them 4 months, but I finally got all my parts back 1000.00 later. This included Deck block/head, .50mm over bored (.020") polished crank, resized rods and hand the piston. I bought the rebuild kit from seller on Ebay that had a good rep for $500.00 which included pistons, rings, pins, head bolts, and most of the gaskets needed to reassemble. Also, bought headers, Aluminum radiator, water pump, thermostat, fan clutch, fan, throttle body and other misc pars for estimated $1000.00. Then add in another 400.00 for custom exhaust I made. So for roughly 3700.00 I have a really nicely moded 525i.



Next up a couple more mods, thinking about the M56 vc as I have a catch can now.
M50 intake conversion
Turbo build
6-speed conversion

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[Chaulklet]

Did you retain the factory DME or did you swap it? I'm trying to figure out what I need to do to do a b25 to b30 swap for the electronics half of it.

[mnewman]

hello, retained DME and flashed the latest ms43 software for the M54B30. did a backup of the B2.5 first ofcourse.

[Chaulklet]

I've been trying to digest the ms4x website, is that where I go to find the proper tune file? Sorry for the basic questions...just want to make sure I'm on the right path.

[mnewman]

Chaulklet --

Sorry for the late reply, didn't see the reply notice. Yes, I have been slowing consuming the info on MS4X wiki as well. These are the files I used below. Not saying "you" should or should not use them but it is what I started with. Hope this helps.

BTW, do you happen to have the intake ducting for the M54B30? I need measurements from the MAF diameter, intermediate hose, and hose to throttle body.

XDF https://www.ms4x.net/index.php?title...30069_512K.zip
BIN https://www.ms4x.net/index.php?title..._M54B30_US.bin

*If you decide to flash t0 the latest version (MS430069), please do so at your own risk, and use garageFlasher or simular to perform a 512K backup of your ECM before doing anything else.

[Chaulklet]

I dont have a B30 yet so I cant take measurements for you, but when I did have parts side by side its roughly 1/4 to 1/2 an inch larger for the intake parts. I believe the throttle body is the same size however as I was able to test my lower intake boot on the B30...

Seeing as you did some flashing yourself, What all entries needed modified in the bin file? All I changed was the VIN with the hex to decimal converter, EWS bypass, and checksum bypass but the car still wont start. It looks like the ISN needs changed as well?
If I can get this guys car running for him he will have a free B30 engine for me to take off his hands so I really need to get this figured out haha.

[mnewman]

So I ended up doing the M50 Intake conversion with custom ducting so no longer need the measurements, but thanks. FYI, the Intake, TB, injectors, and ducting are completely different between the B30 and B25. Did you do a backup of the ECU first? Is this the original MS43 in the car that you are flashing? I didn't need to do a 512K flash as the original MS43 for the car was used. All I needed to do was flash the latest M54B30 BIN (069 by choice). So for me I updated and flashed the M54B30 v069 to the M54B25 ECM.

Also, as a side-note this time around R&R'n my engine I crossed up 2 connectors (2 if the 499 connectors can be accidentally crossed up) which blew the main 35amp fuse for the ignition (in ECM tray) resulting in a no-start. Have you tested to make sure you have spark?

[Chaulklet]

The original ECU had oil travel up the harness and it burned someone out on the board, it had a nice burn mark when opened up. I can still read it and pull the original data off of it. Should I do a full backup of the original ECU and write that to a replacement? The car was running prior to all of this but #5 and #6 had no spark, we opened the case and saw it was burned so we assume thats why.

Post some pics of your intake, I'd be curious to see how it turned out!

[mnewman]

Assuming, you have probed Cyl #5/6 for signal, check coils, and checked continuity in wiring back to ECM, I'd be leaning towards another MS43 after you mention burn marks on the board. Get a MS43 M54B30, make sure the car runs first so you do not have so many "Cats to Heard". Once you know you have a running engine then flash out anything you need to. You can find one with EWS already disabled for a about 150.00.

[Sam Son]

quick question. If swapping a stock M54b30 into a 525 car. It should be completely plug and play to use the stock b30 DME correct?

asking for a friend

[mnewman]

I am no expert, but I think one would need to flash the stock ECM for EWS VIN or disable altogether. There's a good amount of information that might assist your friend here. https://www.e46fanatics.com/threads/...tware.1082287/

Hope this helps,

MN

[effduration]

quick question. If swapping a stock M54b30 into a 525 car. It should be completely plug and play to use the stock b30 DME correct?

asking for a friend

NO.

If you are swapping a B30 into a B25 car, you need to use the B25 DME. The B30 DME will not work with EWS, etc. in the B25 car.

It should start and run fine on the B25 tune, and I would get it running on the B25 tune...

After its sorted, you can then flash the B30 tune to the B25 DME and use the B30's intake, TB, etc.

[mnewman]

You could make it work, just need to flash the EWS and VIN for the 530 ECM. I literally dropped a 530 ECM that I have laying around, EWS deleted and it fired right up no issues. But like "Effduration" mentioned the easy route is to use the 525 ECM, get it running, and then flash the 069 version 530 Tune to the 525 ECM. If you read posts in this thread, it is exactly the route I took. Good luck!

[Sam Son]

NO.

If you are swapping a B30 into a B25 car, you need to use the B25 DME. The B30 DME will not work with EWS, etc. in the B25 car.

It should start and run fine on the B25 tune, and I would get it running on the B25 tune...

After its sorted, you can then flash the B30 tune to the B25 DME and use the B30's intake, TB, etc.

You could make it work, just need to flash the EWS and VIN for the 530 ECM. I literally dropped a 530 ECM that I have laying around, EWS deleted and it fired right up no issues. But like "Effduration" mentioned the easy route is to use the 525 ECM, get it running, and then flash the 069 version 530 Tune to the 525 ECM. If you read posts in this thread, it is exactly the route I took. Good luck!

So I wouldn't need the b30 DME/ECU at all? Retain stock b25 computer and just flash the software? Seems simple enough.

I know Porsche DMEs will allow for a 10% change in displacement without any software adjustments.


Thanks for the info gents

[mnewman]

Another late reply, not getting email notifications or missing them in SPAM. Yes, it should be plug and place for a basic start. From there, I would recommend getting the M54B30 BIN and flashing to your existing ECM. As mentioned the Intake and Injectors and ECM parameters are different but it should run, but I would not drive it like that. Assuming you swapped a complete M54B30 including intake, TB, injectors, MAF and other items, once you flashed the M54B30 BIN you would be good.

Hope this helps!

Mike

[Sam Son]

Thanks for the info!

[chuckesteeze]

Since you've done this a few times, I'm wondering if you could say what to watch out for when swapping a ZHP specific M54b30 into an E39. I just got my ZHP b30 that'll be going into a 525itA, along with ZF manual trans. In looking through some other threads, it's apparent I'll need an E39 specific oil pan and 530 specific airbox/MAF, but is there anything else? Since those later E46s ran MS45 instead of MS43 I'm worried about various sensors and stuff not fitting. I can move things from my old b25 as need but would ideally have the b30 completely ready before the old engine is out. Thanks!

[mnewman]

Since you've done this a few times, I'm wondering if you could say what to watch out for when swapping a ZHP specific M54b30 into an E39. I just got my ZHP b30 that'll be going into a 525itA, along with ZF manual trans. In looking through some other threads, it's apparent I'll need an E39 specific oil pan and 530 specific airbox/MAF, but is there anything else? Since those later E46s ran MS45 instead of MS43 I'm worried about various sensors and stuff not fitting. I can move things from my old b25 as need but would ideally have the b30 completely ready before the old engine is out. Thanks!

Hi --

I am going to try and steer you in the right direction.

1. As you mentioned the Oil pan will need to be swapped from your B25 to your M54B30.
2. If you plan to Turbo your car in the future now would be the time to either TIG a oil return or bulkhead fitting through the oil pan. I have to pull my motor to do this very thing, wish I would have thought about it. Just cap it off with an -AN cap fitting until you decide.
3. I am almost certain everything upstream of the head need to be M54B30 (Manifold, throttle body, MAF, and piping to air box)
4. Swap over all of your sensors from the B25 to the M54 or verify connectors all correct.I seem to remember having to swap a couple over.
5. Rebuild the VANOS on the doner motor.
6. You need M54B30 Injectors (purple ones)
7. FLASH MS43 with M54B30
8. No specific tuning needed for the increased lift and duration of the Exhaust Cam (Basically the difference between a ZHP and non-ZHP). But you could squeez a little more out with specific tuning.

All that I can thing of right now. PM me if you need more info or questions. Good luck!

Mike

[Sam Son]

Has anyone completed a M54b30 swap into a touring? Curious if the extra grunt is worth it over a M52tu

[chuckesteeze]

Hi --

I am going to try and steer you in the right direction.

1. As you mentioned the Oil pan will need to be swapped from your B25 to your M54B30.
2. If you plan to Turbo your car in the future now would be the time to either TIG a oil return or bulkhead fitting through the oil pan. I have to pull my motor to do this very thing, wish I would have thought about it. Just cap it off with an -AN cap fitting until you decide.
3. I am almost certain everything upstream of the head need to be M54B30 (Manifold, throttle body, MAF, and piping to air box)
4. Swap over all of your sensors from the B25 to the M54 or verify connectors all correct.I seem to remember having to swap a couple over.
5. Rebuild the VANOS on the doner motor.
6. You need M54B30 Injectors (purple ones)
7. FLASH MS43 with M54B30
8. No specific tuning needed for the increased lift and duration of the Exhaust Cam (Basically the difference between a ZHP and non-ZHP). But you could squeez a little more out with specific tuning.

All that I can thing of right now. PM me if you need more info or questions. Good luck!

Mike

Thanks a bunch! Definitely some useful info there, and I may indeed be reaching out again later.

Has anyone completed a M54b30 swap into a touring? Curious if the extra grunt is worth it over a M52tu

Having owned a 530i and this 525iT at the same time, I would say absolutely worth going up 0.5L (weight difference taken into account). I also have a buddy in town who turned his 525iTA into a 530iTM and he's considered it well worth the time and expense.

But if you've got a 528iT then the small displacement gain may not be worth the headache of putting an M54 into an M52 car. A lot more coding and stuff involved with that swap.

[Sam Son]

It's not so much the added displacement but on paper there is a decent leap in power and torque from the M52tu to the M54b30. Just wondering if you can actually feel that from behind the wheel. From what I've read the wiring/ecu update isn't that extreme. I assume this is because the two engines are near identical.