Conversion BMW E46 330i Touring with our flywheel article 639

2. Tools & materials

You will need standard tools and a few specific aids for the conversion. The following has proven itself in practice:

• 19 mm socket for cardan shaft and gearbox bearing

• 12 mm multi-tooth or hexagon socket for pressure plate (depending on clutch set)

• Torque spanner with employment until at least 110 Nm

• Medium-strength screw locking adhesive

• Gearbox jack or alternatively, a sturdy trolley jack with a wooden base

• Motorised support or crane (Recommended for longer gearbox separation)

• Clutch centring tool for correct positioning of the friction disc

• Brake cleaner & cloth

• Wear safety goggles when removing and handling brake cleaner!

Once the gearbox has been removed, you will see the clutch pack with pressure plate and friction disc. Loosen the pressure plate bolts crosswise and evenly to avoid tension. Leo's vehicle (BMW E46 330i Touring, built in 2001) showed the typical signs of age: slipping clutch, vibrations when starting off - and the flywheel already had clearly noticeable radial play. Result: Replacement absolutely necessary!

Now remove the original dual mass flywheel and check that the drive bolts on the crankshaft are in order. The Epytec flywheel is supplied with new bolts (strength class 12.9) - always fit these using medium-strength threadlocking adhesive!

Fit the clutch kit (e.g. Sachs XTend or LuK SAC), centre the friction disc correctly, screw on the pressure plate crosswise using the screw set supplied. Make sure that the disc spring responds properly and that nothing is tilted.

When reassembling the gearbox, make absolutely sure that the release bearing runs correctly on the guide sleeve. Operate the clutch and check the gear selection - the clutch pedal feel remains true to the original!

Experience: Even with a sporty driving style, the function of the original clutch is fully retained, including a clean grinding point.

Note on the clutch:

Additional information on clutch selection:
Both systems have the same idea: the clutch should last longer thanks to automatic adjustment. Although I personally prefer the Sachs system (XTend Type I), there is a small peculiarity when mounting it on the EMS. The installation regulations with regard to the housing stop are violated. The reason: The housing stop (marked red in the picture above) can no longer make a clean stop if the support ring of the EMS is no longer flat. This means that correct resetting of the adjustment mechanism is no longer guaranteed. In such cases, the LuK clutch kits with SAC system are more suitable.

Important to know: Clutch kits which, according to LuK and Sachs, are approved for models "up to 02/2003" (regardless of whether 228 mm or 240 mm), contain a 10-tooth friction disc. This only fits the 5-speed gearboxes S5D-250G and S5D-320Z. However, if you have an E46 325i or 330i (M54) with a 6-speed manual gearbox or SMG, you will need the clutch kit "from 03/2003". This has 22 teeth and fits on the main shaft of the GS6-37BZ (6-speed gearbox 330i/325i). In the E36 models with M52 engines, the S5D-250G is usually installed again - so the 10-tooth disc is also mandatory here.

For a sporty driving style, I clearly recommend the 240 mm clutch kits from the E36 328i, E46 328i and 330i models. This enables better power transmission even with higher torque. The 228 mm clutches (sometimes also called 230 mm) from the smaller 6-cylinder engines (320i-325i), on the other hand, tend to slip quite quickly with aggressive driving or engines with more power.

• 5-gear (240 mm):
  Sachs: Art.-No. 3000 970 095
  LuK: Art.-No. 624 2333 00

• 6-gear (240 mm):
  Sachs: Art.-No. 3000 970 139
  LuK: Art.-No. 624 3158 00

Conclusion:
The quality is top, the workmanship is highly commendable and the accuracy of fit leaves nothing to be desired - this also applies to the original M52/M54 clutch kits. In addition, the weight is pleasantly light and the price is fair. However, there are two small points of criticism: Firstly, the weight saving means that the necessary support for the housing stop is missing on the Sachs kit. On the other hand, there is no hole to pin the flywheel. This means that in future you will have to rely on a dial gauge in the first cylinder when working on the timing (timing chain, VANOS).

I hope I have been able to help you with this information and perhaps motivate some of you to think about EMS.

4. Sources of error & Troubleshooting

If unusual noises or grinding noises occur after the conversion, check:

• Whether the EMS is correctly positioned on the crankshaft

• Whether the clutch basket has been mounted braced

• Whether the friction disc is correctly centred

• Whether screw locking was used (absolutely necessary!)

If it is difficult to change gear, there is usually a fault in the release travel or a poorly centred friction disc. In this case, we recommend dismantling everything again and reworking it properly.

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5. Safety & liability

Safety has priority!
Always use jack stands or a lifting platform when working under the vehicle. Never work with jacks alone!
Wear safety goggles when cleaning with brake cleaner!

Disclaimer:
The conversion is carried out at the user's own risk. Epytec accepts no liability for consequential damage caused by improper installation. All work should only be carried out with a full technical understanding or by a specialised workshop.

6. FAQ for the installation instructions

Question 1: Does the EMS also fit vehicles with a 6-speed gearbox (GS6-37BZ)?
Answer: Yes, but please note that clutch kits from 03/2003 onwards must be used with 22-tooth discs. The earlier 10-tooth discs are not compatible.

Question 2: How does the EMS change driving behaviour?
Answer: The engine revs up noticeably more freely and the response behaviour is significantly improved. Despite the 4 mm lower height, the pedal feel remains virtually unchanged.

Question 3: Can I continue to use my old clutch?
Answer: In most cases, yes! The Epytec flywheel is designed to be compatible with the original pressure plate and friction disc. You should only choose a new set if there is already heavy wear or the wrong clutch is installed.

Disclaimer
Please note that this installation is carried out at your own risk. Epytec accepts no liability for damage or injury resulting from following these instructions. Make sure that you understand all the steps and take the necessary safety measures.

And ready ! That's it!
We hope that you have now successfully installed everything. If you have any questions or anything is unclear, please do not hesitate to contact us.

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