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      10-27-2021, 02:03 PM   #1
Papaaratsio
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Cool E85 3.0i to 3.0si conversion

So, last month got my 2006 E85 3.0i with 6 speed Automatic transmission.
Everything is fine, but need more power

I have checked OEM catalogues and notice that all mechanical parts for engine, cooling, fuel system, transmission, differential, suspension era equal, difference is only:
1. Intake manifold - 3.0is has manifold with variable geometry
2. DME units are same except software.

So, locally in my country i can obtain some used manifold (it's mounted at lot of models, and there is no problem to find it, price around 100$), and there are some guy's who can flash the ECU.

So question - has somebody experience for such kind modification? any "submarines" ?
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      10-28-2021, 03:49 AM   #2
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If this is N52 in your Z4 then it's a very common mod in 1 series and 3 series community.

https://www.e90post.com/forums/showthread.php?t=372973

and actually here

https://www.zpost.com/forums/showthread.php?t=455180

PS: I haven't done this myself (yet) but researched a lot in this direction. But since this is my wife's car she keeps not approving this spending
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      10-28-2021, 01:21 PM   #3
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Quote:
Originally Posted by vt100 View Post
If this is N52 in your Z4 then it's a very common mod in 1 series and 3 series community.

https://www.e90post.com/forums/showthread.php?t=372973

and actually here

https://www.zpost.com/forums/showthread.php?t=455180

PS: I haven't done this myself (yet) but researched a lot in this direction. But since this is my wife's car she keeps not approving this spending
Yes, it's N52 engine.
Today found person who will flash for 80$, now have to find intake.

By The way, because of it i have no more wife and drive Z4
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      10-30-2021, 08:50 PM   #4
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Quote:
Originally Posted by Papaaratsio View Post
Quote:
Originally Posted by vt100 View Post
If this is N52 in your Z4 then it's a very common mod in 1 series and 3 series community.

https://www.e90post.com/forums/showthread.php?t=372973

and actually here

https://www.zpost.com/forums/showthread.php?t=455180

PS: I haven't done this myself (yet) but researched a lot in this direction. But since this is my wife's car she keeps not approving this spending
Yes, it's N52 engine.
Today found person who will flash for 80$, now have to find intake.

By The way, because of it i have no more wife and drive Z4
Yes, E85 upgrade is easy. Road is well traveled. Install the three stage manifold and flash the programs available on Bimmerlabs for free.

After that's, look at the transmission tune. Really changes the car. I don't remember what trans tunes for the E85 are posted but all give them a look.
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      11-10-2021, 03:58 PM   #5
Papaaratsio
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Quote:
Originally Posted by rjahl View Post
Yes, E85 upgrade is easy. Road is well traveled. Install the three stage manifold and flash the programs available on Bimmerlabs for free.

After that's, look at the transmission tune. Really changes the car. I don't remember what trans tunes for the E85 are posted but all give them a look.
Thanks for advice.

Today got 3 clear intake manifold from 2008 328i, got DISA-s from 3.0 engine (probably E70 3.0). Transferred all mountings and accessories from original manifold. Cost of parts ~120$

Engine started and car drives without any issues. Tomorrow will try to flash ECU. If everything well be ok, than last step - 3.0si badges
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      11-15-2021, 02:59 AM   #6
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So, finally got it, most hard part of modification was programming.

Here i'll write short steps done:

1. Firs got used Intake manifold from E90/91/92/93 328,330 is same, also from E60 530, E70 3.0si also fits.
2. Got DISA valves from 2008 E70 3.0si, used but in wery good conditions.
3. Swapped manifold. there is no any modification needed, all mounts, all hoses transfers 100%.
4. wiring for internal and external DISA already included with standart wiring, and they are mounted on manifold with some blanking caps. Long wire goes to inside DISA, short one to outside.
4. After this steps car runs without any problems and issues like before swap.

budget: around 120$ for manifold and DISA's. (prices actual for Georgia, not sure about US market).
swap was done by myself, it tales around 1-1.5 hours.

This was for mechanical parts, now for the programming, for me, due to newbie with BMW tools i took for me 4 days. And all problems was because wrong type of cable.

1. Get USB K+D CAN cable, mine was cheap, nothing special. Installed drivers, abd set Comp port to COM1.
2. Downloaded Standart Tools and SP-Daten for E85 from: https://www.bimmergeeks.net/downloads.
3. Followed their instructions 100%. + During install pay attention to use STD:OBD interface, COM1 and !!! mark USB !!! + additionaly copied C:\EDIABAS\BIN\obd.ini file to C:\Windows
4. After installing run Codding Tool, defined NSC Expers, Ediabas, WinKFP - NFS folders ("Default Folder Settings"). Selected SP-Source - Root folder of E85 downloaded from Bimergeeks, then Update SP-Daten, Update WInFKP. This step is important, because much easier to go to next step.
5. Registered at https://www.bimmerlabs.com/ define new project with my VIN and site gave me all necessary file links for codding. configured all settings !!!Only Step 2!!! in thsi manual: https://www.bimmerlabs.com/help#winkfp, no more steps is required.
6. Programming:
- first step MSV70_RSADelete_0049PP0L921S.0pa - unzip to any folder and run butch file. if you got Error 106 it means WinKFP cant find Comport defined in C:\EDIABAS\BIN\obd.ini, check device manager for com port numbering. If you got error Integrity check, it means there is no communication via cable (wrong one, not compatible to INPA). easy check via INPA aplication, if it detects cable and detects Ignition ON. During this flash Fuel pump goes crazy, it's ok it takes 5-10 minutes, don',t interrupt!!!!! you will have process indication, be patient.
- Second step was to flash MSV70_S7623588_30i_to_30si.0da, process runs smoothly but result was not good, car runs but got error SERVICE ENGINE SOON, i have read errors and this says "Codding Missing, Gearbox Control" Suppose this firmware was from manual gearbox, and mine is 6 speed Automatic. But not shure.
- Third and final step was to flash third file MSV70_S7581355_30i_to_30si_ECE.0da. after flashing SERVICE ENGINE SOON gone away. and car runs. now have to test car for several days.

Final step well be buy 3.0si logos, which i suppose is most expensive part of project, there is no used at ebay, and OEM costs 160$ for both.

Thats all.
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      11-15-2021, 11:31 AM   #7
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I am doing the same currently but have run into an issue. The lower PCV valve doesn't have a port to go into the oil pan. I just a regular nut on mine I think. And the upper hose which is shorter and goes into the valve cover is a different size than the 3.0i so the hose won't fit the valve cover.

Did you see the same issue? I have a few pics attached to share.
Attached Images
  

Last edited by AustinZ4; 11-15-2021 at 02:37 PM..
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      11-15-2021, 03:14 PM   #8
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Quote:
Originally Posted by AustinZ4 View Post
I am doing the same currently but have run into an issue. The lower PCV valve doesn't have a port to go into the oil pan. I just a regular nut on mine I think. And the upper hose which is shorter and goes into the valve cover is a different size than the 3.0i so the hose won't fit the valve cover.

Did you see the same issue? I have a few pics attached to share.
Nope. R U sure engine is N52? because in my case hose from oil pan goes to Oil separator, which is mounted backside of intake manifold.

https://www.realoem.com/bmw/enUS/sho...diagId=11_3738
Look at diagram, hose #4 goes to oil pan.

Last edited by Papaaratsio; 11-15-2021 at 03:34 PM..
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      11-15-2021, 03:17 PM   #9
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So some updates after modification, as I mentioned above car runs and drives nicely (best description is - running crazy

But there is one issue, INPA shoes one critical error in DME - Error 2FA3 - Codding Missing.
Which doesn't light "Engine service" warning light. Shure it's because car knows that there is 3.0i engine, but codding is from 3.0si. I'll try to investigate internet what is the solution.
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      11-15-2021, 03:52 PM   #10
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Quote:
Originally Posted by Papaaratsio View Post
Nope. R U sure engine is N52? because in my case hose from oil pan goes to Oil separator, which is mounted backside of intake manifold.

https://www.realoem.com/bmw/enUS/sho...diagId=11_3738
Look at diagram, hose #4 goes to oil pan.
Right. Did your 3.0i intake manifold have that oil pan hose attached? Mine did not, only the one coming from the valve cover.

As per vin check, year (make/model) and realoem I have a n52. And the donor car N52 (a E60 530i) intake manifold fits like a glove.

Last edited by AustinZ4; 11-15-2021 at 03:58 PM..
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      11-15-2021, 05:57 PM   #11
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Quote:
Originally Posted by Papaaratsio View Post
So some updates after modification, as I mentioned above car runs and drives nicely (best description is - running crazy

But there is one issue, INPA shoes one critical error in DME - Error 2FA3 - Codding Missing.
Which doesn't light "Engine service" warning light. Shure it's because car knows that there is 3.0i engine, but codding is from 3.0si. I'll try to investigate internet what is the solution.
The coding error is meaningless, don't worry about it. If it drives you nuts, you can "code" it out with Ncsexpert. Plenty of online instructions for coding your DME.

Essentially, your DME is still coded for a different software than what you are running. No harm, it's just a reference.

I ran with a coding error for months.
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      11-15-2021, 06:02 PM   #12
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Quote:
Originally Posted by AustinZ4 View Post
Quote:
Originally Posted by Papaaratsio View Post
Nope. R U sure engine is N52? because in my case hose from oil pan goes to Oil separator, which is mounted backside of intake manifold.

https://www.realoem.com/bmw/enUS/sho...diagId=11_3738
Look at diagram, hose #4 goes to oil pan.
Right. Did your 3.0i intake manifold have that oil pan hose attached? Mine did not, only the one coming from the valve cover.

As per vin check, year (make/model) and realoem I have a n52. And the donor car N52 (a E60 530i) intake manifold fits like a glove.
There were two versions of this manifold, one for the early engines with the pcv external to the metal valve cover and one with the pcv internal to the plastic valve cover.

Early versions had one port on the manifold while the latter had two.

I've seen a few people create work arounds to the problem, several posted on the E90 sections
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      11-16-2021, 10:15 AM   #13
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Since my Z4 doesn't have a oil pan hose for the intake manifold drain, looks like I'll be installing an oil catch can to get around this issue with some hydraulic hose connections. Joy...lol. But shouldn't be too difficult.
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      11-24-2021, 08:29 PM   #14
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Got the tune done and car restarted. Ran some inch long hydraulic hose to connect intake manifold to valve cover. Blocked lower intake manifold drain (will replace with catch can upon arrival). No engine codes and it's running good. A DISA valve is bad so I'll have to swap that out, but no big deal.

As above, simple process. Hooked the car up to an external power source to maintain the 12V. Download the E85 ECU tune from Bimmerlabs and extracted them. Ran WinPFK and followed their instructions. Imported said files. Ran the unlock bat file. That took 3-4 min. Ran the i to si conversion bat file. That worked.

Next up is the trans tune. Hopefully get this thing shifting faster and a bit more throttle response.

Last edited by AustinZ4; 11-24-2021 at 08:36 PM..
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