BMW E39 Manual Conversion (Wiring/Coding Instructions included)
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- Опубліковано 3 лют 2021
- Automatic to manual transmission swap on BMW E39 Wagon
Wiring:
Reverse switch: 1 pin goes to ground, the other pin goes to the cluster( high cluster pin 25 of blue connector, low cluster pin 4 of black connector)
Clutch Switch (New style 4 pin switch that mounts to clutch master cylinder):
Purple/White taps into Purple/White of brake switch
Brown/Black taps into Brown/Black of brake switch
Blue/Black goes to pin 8 of ews wiring
Blue/Brown goes to pin 23 of X60004 (40 Pin connector on DME)
The way I did it to eliminate running wires:
On auto trans cars, pin 6 of ews goes to pin 3 of x70003 (52 pin blue connector on egs/tcu). So I took pin 3 of the EGS connector and ran it to pin 23 of dme X60004 (40 pin connector). And then took out pin 6 of ews connector and ran it to blue/brown of the clutch switch. Pin 6 of ews is no longer needed when the car is converted to manual.
On auto trans cars pin 18 of x70003 (52 pin connector on egs/tcu) goes to pin 3 of x1600 (3 pin purple connector at the gear shifter). So I ran pin 18 wire to the reverse switch wire and pin 3 wire of x1600 to the cluster.
For the reverse switch I cut the two green wires on the auto trans connector and used those to wire to the reverse switch. One of the green wires went to pin 18 wire of x70003 and the other green wire went to a ground.
Coding with NCS Expert:
1. click File, Load Profile, Expert Mode, OK
2. Click the VIN/ZCS/FA
3. Click the ZCS/FA f. ECU
4. Click E39, OK
5. Click KMB (or IKE), OK
Remove AT option from ZCS in KMB:
1. Click the Enter ZCS
2. Click E39, click OK
3. Edit the ZCS: subtract 1 from the 3rd digit of the GM field (example go from 5 to 4). And subtract 1 from the 4th digit of the SA field (examples go from 4 to 3)
4. Remove the last character from the GM, SA, and VN fields, check the Calculate checksum box, OK
5. Click Back
6. Click the Process ECU
7. Click the module to code (IKE or KMB for cluster), OK
8. Click the Change Job, click ZCS_SCHREIBEN, OK
9. Click the Execute job
10. Wait for the Coding ended status
Remove AT option in EWS
1. Click the Change ECU
2. Click EWS, OK
3. Click the Execute job
4. Wait for the Coding ended status
5. Close NCS Expert
Recode the whole car( this will remove any custom coding done previously):
1. Start NCS Expert
2. In the top menu: click File, Load Profile, Factory Coding, OK
3. Click the VIN/ZCS/FA
4. Click the ZCS/FA f. ECU
5. Click E39, OK
6. Click KMB (or IKE), OK
7. Click the Process Car
8. Click the Code Car
9. After all modules are coded you are done.
Use WINKFP to flash new manual ZUSB file: You can use RealOEM to find the correct one for your car by putting in all of your cars information (NOT VIN) but selecting manual instead of automatic. Then go and find the “programmed DME” and the last 7 digits of the programmed DME number will correlate with the ZUSB needed.
Chase Bays Stainless Clutch Line:
www.chasebays.com/products/ch...
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Thanks for watching! If you need them, Wiring/Coding Instructions are in the description!
You guys are so thorough. Great job working on all these BMWs. I have a question for you. My son’s E39 M5 is having some electrical issue with his lock system not working. He’s tried all the programming on the key fob but with no luck. If you guys could do video on how to troubleshoot this issue, that would be great.
Yo bro I've got a bmw e46 323ci ci but my dual vanos is not kicking can you perhaps give me a reason why it's not working
How much do you charge ?
You mentioned changing a letter on the GM? I’ve converted my 840ci m62 to a manual 6 speed but it idle hunts for the auto and has ‘trans fail safe’ on the mid. I have an autologic box here so I can change the vehicle order number
Is this all the same for the 540? I’ve done the whole manual swap. Coding. And now I’m stuck on the wiring part. I just cannot get my car to turn over. Or even get the starter to kick. I think the car still thinks it’s in neutral - :/
This is what UA-cam is all about-down to earth content. Not flexing the newest super car for the views.
Appreciate this man!
Yes sirr
Lol ok?
ok. not everyone is into super cars. i for one, don't give half a shit about super cars. even if they were "down to earth cars"
I've an e39 520i wagon, m sport, manual. For you Americans it's got the 2.2l M54. 170bhp. E60 540i short shifter, vanos rebuild, billet disa valve, straight piped, michelin pilot sports and E46 M3 wheels (needed adapter spacers to fit e39 hub) and i spent the last month using a dish sponge to dye the entire interior BMW cinnamon. Bought it for €900 and she's my baby. When I'm rich I'll treat her to a 3 litre. Brilliant cars. Almost as fun as an E46 but way more comfortable. Perfect daily, perfect project. Just stay on top of everything like the water pump, vanos, radiator, stuff like that and she'll never let you down. This channel has been essential in owning an old BMW. Much love
I don't think you understand how much your videos helped, from replacing the csb, to replacing the rear main seal to the steps for the swap. Literally a lifesaver 🙌. Only thing I would change is to specify that the newer model clutch switch has only one connector on the back of the master cylinder rather than 2 separate blue and red sensors on metal brackets for the old version.
Recently bought a 39 wagon, auto. I’ve used your tutorials for majority of my repairs this far. 1000% will be using this one too. Thanks again Mr.HeyGuysWelcomeBackToShopLife
This is top level instruction. This will help greatly when I finally drop the 4.6 motor in my 4.4tu wagon....
Nice video...Hope he likes the 3.46 diff...A lot of revs on the highway...
Nice work guys! It’s refreshing to see your wealth of knowledge and also fixing somebody else’s mistakes.
Thank You! Always happy to be able to help others!
@@ShopLifeTV what's the cost of something like this? I was thinking about swapping my auto in my e39 540i
Great video man, was nice to see the kid helping you out too, sometimes I feel like we're the last of our generation to not mind getting our hands dirty. And also Selena on hand to help out, you're a lucky man ;) Keep up the good work both of you!
Thanks! Definitely agree with you on that, not many people want to get their hands dirty anymore
Wow, that's a beauty guys. And a very nice manual swap DIY! Dutch regards, Nico.
Let me say this. Happy Monday. @shoplifetv you sir are a Legend. I followed your instruction step by step along with a few other youtubers and i completed my swap 2 days ago. Shop Life's wiring is spot on and car started right up. I am not sure if my reverse lights work just yet as i haven't coded the vehicle. Once thing i would like to mention to others out there. is I have a 2000 528i and i wish this video showed how to connect ncs expert to the car. I have read that we need to connect via the round 20 pin connector under the hood to code the car as we can not code the car thru the obd port in the drivers foot well area. I had a few hiccups with how to route the hard oem clutch line, bleeding the clutch slave was a pain, and the mounting the transmission to the engine was a nightmare. But to anyone out there IT IS DO ABLE. I did it over the course of 5 days by my self with a jack and a mechanics tool set. It is not rocket science, follow this mans lesson, uses 50's Kid videos as well and get a general understanding of what you will be doing. Car absolutely drives fantastic now. Love it.
Thank you for your summary of coding instruction. I could convert my 528i sedan to manual without any problems or hassle 🙌
Beautiful Touring! Jason at Alpha Motorwerks is AWSOME!!! I have been in R&D mode for this moment for 4 yrs since buying the car. I tracked this guy from Cali back to NC and connected with him. I knew from watching many of his vids that he was competent and thorough. Great work! Now I can finally add my M\\\ front bumper and steering wheelThank you, Jason and SELEEENA!!!
Thanks a lot! It was a pleasure working on your car.
@@ShopLifeTV for sure! Competence over $$$
That was an awesome video, the in depth wiring tutorial was really amazing, I wish my mechanic was half as thourogh as you are
Great video, you do a lot of things right that other channels do wrong. You are a great host. Subscribed!
Love when you upload man. Keep it up!
Hats off. You know your story when it comes to bmw.🤜🤛🙌
Great vid man! Family friend gave me an E39 530i for free and I’m strongly considering doing this. After manual swapping my 335i I’m convinced it’s the way to go
Great looking wagon. Love those m-parallel wheels!
Great job bringing in beautiful Selena to help with the heavy lifting. Glad to see "Wonder Woman" wasn't too busy to chip in. Lol...
This video can also be useful in mating a nonstock BMW transmission to one of these cars.
Thanks Brian! Hope all is well!
Thanks for taking the time to make this! I just bought a manual e39 sedan as a donor car to manual swap my wagon and this video is a game changer. You hit every relevant point and gave some amazingly detailed information to help everyone else out. Much love and keep up the great work!
Does everything from the sedan fit on the wagon
@@ZaysSlow335 all of the drivetrain components are the same as chassis is the same. The front trim for the swap should swap with the sedan however the doors and backseats may be wagon specific. I ended up selling the sedan to fund my drift car but all the stuff to swap to manual should fit
@@Varsn101 appreciate you
Great video and great content, including GREAT WORK...much success to you!!!
This guy is great, I lucked out and got a 528it manual. But my rad kinda wants one so I might buy one and swap it
My 528iT uses that same 3.46:1 final ratio, but I used the Getrag 250 gearbox, which has the same internal ratios as the ZF320 .
It's proved to be a pain in the neck on the highway (frantic), and first gear is useless for anything short of pulling stumps. I should have used the 3.23:1 final; more in line with the touring nature of the car.
Also, the pre-facelift clutch/brake reservoir is identical. The upper plastic is the one that needs to be cut.
Love your content!
Impressive that's a job well done.
Great work. Love to watch your vids
Love you man you do a really great job and very well explained
Nice! Have been looking for an e39 touring in 🇬🇧 nothing this clean however great video bro
Great vid, you do a great job explaining things
Great video. I had my E39 Touring converted a year ago and I'm loving it!
what model touring do you have?
@@williamboyd795 528i
Did you follow this video to do the 5 speed swap I'm a little confused on the clutch switch wiring and think I got it wrong. I try to code it with ncs expert and it has a fault for no communication with the egs so won't let me finish coding
YOU ARE ONE GOOD ENGINEER MY FRIEND
Been waiting for this😍❤️
you look healthier then when you lived in LA. Great shit dude
Haha thanks man, I've put on 30 pounds and been working out like crazy! Feeling great!
Great video.I'm potentially buying a 523i estate (wagon) with an auto transmission. I'll probably be happy with it, as I won't be driving it much, but knowing the conversion can be done easily enough is a bonus. When I say easily enough, I mean when people like you do it! I couldn't imagine me doing it ever! LOL 😅
Great video! 👍
Seems like everyone is doing auto to manual swaps. But I just want a stronger auto trans.
This is awesome. Time for my e39 to get what it needs.
When doing work on those connectors, I bought a Wire Terminal Removal Tool. It's 60 pieces of assorted picks to help remove the pin inside the connector. $12 bux. A pick will work fine, but for the money, you'll have a lot of options for removing a pin without damaging it.
Hey man, great video! I love all the BMW videos you give to us…so much helpful information!! I do have one question though, about the wiring. I’ve done the manual swap on a 2003 540i mSport and there is a blue with black stripe wire in pin 8 of the EWS from the factory. Does pin 4 of the clutch switch become spliced to this wire? Or does it replace it? If it replaces it, is there anything that needs to be done with that blue wire with the black stripe? After looking at the Bentley diagram for the EWS, I can see this wire links the EWS to the transmission range switch for the automatic, so I’m assuming it’s no longer needed, but the more clarity I can glean on this the better. Anyway, thank you for the videos and your thoughts and time, and I look forward to seeing what you’re doing next! Cheers- Coop
Daaamn that things clean
Very cool video, thanks.
Don’t have time to watch this tonight but I really hope this can help me out. I gotta 01 E39 that’s auto and I’m doing a turbo ls swap/ also converted it to manual but I don’t know anything about coding, DME and stuff like that
Hey, great video man, thanks a lot for all the information
For the wiring, does it changes for a 530d ? If yes, what changes please ?
Thanks man, keep up the good work 👍
This guy is a legend... can you pop over to the UK and sort mine?
Great video! As always! For the future, it would be a great idea to use a steel clutch fork pivot pin from an 850i instead of brass. Brass is very weak and wears down quickly.
Luv u, helped me a lot
Very nice video. I wonder are those wiring stuff like same for E53 3.0d too?
awesome job
Great video
Great video. I'm looking to attempt this conversion myself and would greatly appreciate if you could add a link to the clutch line you used so I could use the same one. Thanks in advanced.
For anyone in the future that is going to do the swap, if your car won’t start it’s because of the clutch switch. Just bypass it by taking 12v from the brake switch and placing a wire to the blue and black cable to the EWS
Thanks for the video! This is giving me the confidence to do the same swap to my wagon. Can you please share the name of the clutch switch wiring harness adapter you used for swap? Thanks!
Great work!I want to question you is for e38 the same wiring because I bought a 730d with manual swap but the reverse light,pdc and the tempomat are not working
Awesome video I just did a M54b25 swap into a m52tu e46 323i Japanese spec and also swapped my 5 speed over with it im having issues wiring my reverse lights do you know of any difference from pre facelift to post face lift
Wow its clean
Last step on wireing is to bridge the two wires from the clutch (vi/w and br/bl) with the vi/ye wire from the brakeswitch? Is that right? Can Not see the wire, in the description there is no information about that step. Thanks for help!
Thanks
Hey, nice video! Is the wiring the same as the wiring from prefacelift 99` Model with M52TU? Greetings vom Germany
Subbed man! I have a IS300 Sportcross Wagon, hoping to do a manual on it aswell
Good work man! Have you ever done a 4.6 swap on a 540?
Awesome job as usual! Just one question did you change out the rear main seal when you swapped the transmission?
Thanks, and yes all of the seals even the ones on the transmission were replaced
Hey shoplife, is your new shop in North Carolina up and running? I have a 540iT that i'd love to have you look at/work on.
Lol this is beautiful I currently drive a 2001 325i e46 wagon m sport edition nd have been curious bout swap also mines silver nd has 219k on the engine 😆 beautiful car ...does this swap apply to that model also ? 325i 2001 e46
،good work i want ask the 6 speed for e39 m5 can i swap to e39 540i m62 its fit?
Brilliant work! Do you guys think it is possible to convert 2016 BMW M6 GC? Where are you located?
Thank you so much for this great video. I did this on my 535i e39 (european model) and I had no crank no start. This is due to the fact that European models don't use the clutch switch as a safety switch. I took power from the brake switch to the EWS to solve the problem, and it worked. Coded the car, everything works nice except for the cruise control which won't power on. Any clues? note that the reverse switch works, and the PDC as well as the car is coded as a manual, using NCS expert.
Awesome video! What was the cost of the manual swap?
Would the wiring be the same for any manual transmission? Like if I swapped a t56 from a Chevy would I follow the same wiring instructions? And you said the wiring is for the cruise control, do I need to do the wiring still if I don’t care for cruise control?
Just a warning for all e39 touring owners. The rear jacking points rot. So avoid jacking up from it. For the UK owners anyway.
If you have a manual donor car can you take the few wiring harnesses out and swap them? Or are they integrated into the main harness? I’m trying to do this same swap on my 03 540 wagon. Have a full donor car so I can take everything
will your cruise control work if you follow the video? and does the video itself contain every wire needed to get the car running
Hi it might sound stupid but do connect all the blue plug back to the DME box after wiring
Just trying to understand. when you are finshed, do you plug everything back into the auto trans module?
I have an e39 wagon 525 just like this one, what manual trans did you guys end up getting? Zf or getrag? Not sure which one will fit the M54
One question, In the Engine side there's no modification needed???, What i mean is the pilot bearing in the clutch kit will go in the automatic engine?? I'm asking because I have an E39 factory manual transmission. I'm case I need a new engine , can I buy an regular automatic car engine and it will Fit with no issue?
I am coding my 1997 e39 tds to manual. I succefully coded the GM string by subtracting 1 from the 3rd number (from 8 to 7). However, I am confused on what to do with the SA string because I am supposed to subtract 1 from the 4th number but that number is 0? how do i subtract from 0!?
I have a 150K BMW 525it wagon.
Is that engine too anemic to actually enjoy
the gear rowing?
It's last year built and I drive it all over.
Old school guy who learned on 3 pedals.
Did you replace the oxygen sensor wiring harness to the manual trans oxygen sensor wiring harness?
Does your clutch master cylinder have some wiring going to it? I have a 02 525i I'm converting to manual and my clutch master doesn't have wires going to the master cylinder only the switches
I need to manual swap my e39 wagon soon, any idea what suspension he’s running here?
Do you have any info on parts needed and what vehicles I can source them from to manual swap an e85 z4? We already have the m3 6 speed
Hey bro i have an e46 330d 2005 here in uk.. i cant get my pdc to work and have done the reverse signal to the relay in dme box .. do i have to wire from fuse box to instrument cluster ??
if i were to swap a engine from an auto 540 to a manual 540 would it just fit in and shift fine or would it need a tune etc?
Just curious but here in NM it’s hard to find parts from a 5 series but 3 series are easy to find in manual will parts from the 3 series work for a 5 swap
May I ask do you take on new customers Looking at getting a e39 530i that I want to convert over to manual.
Is the e60 530i will be the same , in coding and programming?
Is any source that I can go to , for my e60
Hello.
I'm switching from an automatic to a manual gearbox.
I've done it on some E46 and it went well
but this one I have some doubts
mechanical part is completed
Now I have some electrical problems.
I'm talking about a 1996 520i where the cx aut. no
is the same as in your video, it's just a long chip instead of several smaller ones (blue)
can you help me to complete the assembly
thanks
Hey Do you know anything about what wiring might need to be done to get a manual swapped 05 bmw 645ci e63 started
Anyone know if the trans support brace is different between auto and manual? Also, THIS IS A MS43 CAR , WIRES ARE DIFFERENT THAN 2000 or earlier e39's. my auto trans wires are totally different only one big connector on the trans controler in the dme box.
Can I run wires from the reverse switch directly to the dash cluster and ground?
how much do a conversion cost
auto to manual on average ?
How much did you charge? I want to manual swap my e90 328i but I don’t have the proper tools much rather have you do it, but would like to get an idea of how much it would be
I would like to know what the cost of a manual conversion would be? I'm from South Africa but I would just like to get an idea of cost.
I have only 3 pins in the clutchswitch..the one that should go to ews is missing
This might be a dumb question, but are the wiring instructions the same for a sedan?
Bro what’ cost am I looking at for an auto to manual conversion for my 540i touring which also happens to be black
Hey bro what would getting a manual swap cost me? I might be looking into it in the future.
Where did you get the pin out diagram for the transmission.
what transmission did you use and differential? thanks
could you swap 2008 e60 six cylinder turbo engine and auto transmission into my e39 which died of timing chain failure
Is thus the same procedure for 2002 525i e 39
Great video, I manual swapped my 540i last year but forgot to sort the cruise control. What is needed to get that working? Or can you bypass the DME looking for the clutch switch?
Hi, did you end up finding how to make the cruise control work? I have this issue.
@@adrenanic5871 I haven't bothered to fix it yet but I believe all I'm missing is the clutch switch for the cruise control, I never ordered one.