[gixracer]

So this is not my first rodeo.

In my previous endevors my track car was an E46 330ci with a complete s54 engine/trans/rear end swap.

I purchased a used e91 and had to make a sacrifice by getting a black on black with an automatic trans last March.

I hurt to do it because I enjoy driving a manual on the track and as a daily driver. The wagon has been a hoot to drive since I put the staggered VMR's on along with H&R cup kit with their sport springs. Interesting enough the day after I ordered the suspension, the front right strut blew a seal. Crappy Michigan roads!

What am I doing? Well my donor/next project arrived today. Its a salvage 2011 N55 135i with sport package and a manual trans. This is going in the wagon! The damn Euros got them but here in the states no go because wagons are not hip. I thought about doing the s65 swap but then i would "need" the body conversion. This is my summer daily driver and no sense in going overkill.

Diving into the Parts list the trans motor rear diff are an easy straight swap. Drive shafts dont match cause the 335 has a different coupling to the diff than the 328. I have the correct drive shaft en route, it's a standard E90 335i manual trans.Exhaust is going to be custom for a while because its another $1000 to get a euro dual exit, plus I dont mind the sleeper idea.

[elons335i]

Subbed. Also digging the f4 tucked away in the corner.

[CantCatchMe]

This is awesome! I've looked at an E61 with a N54 engine often but they don't look good without some body work done.

I can't wait to see some videos or in person. What city are you located in?

[gixracer]

Originally Posted by CantCatchMe

This is awesome! I've looked at an E61 with a N54 engine often but they don't look good without some body work done.

I can't wait to see some videos or in person. What city are you located in?

south side of Waterford.

[9krpmrx8]

Nice man, great project. I love the E91, I would of bought one if we could have got one with the N55.

[ctuna]

The Europeans use to be able to get them
with the bigger and turboed engines.

[tlow98]

Awesome swap! Looking forward to your build.

[slupie]

Awesome project, I guess if you can't buy it then build it. I love my E91 but sometimes I wish I had few more HP's and Torques.

[mike-y]

Nice. Is swapping out the fuel system is required too, right? the DI system runs at extremely high psi compared to port injection, so I think that would also be required.

[gtvr6]

Subscribed. Good luck - this looks like a fun project.

[Memaxndapickel]

So jealous man! I love love love wagons and power! Subbed

[E91 M Sport]

Originally Posted by gixracer

So this is not my first rodeo.

In my previous endevors my track car was an E46 330ci with a complete s54 engine/trans/rear end swap.

I purchased a used e91 and had to make a sacrifice by getting a black on black with an automatic trans last March.

I hurt to do it because I enjoy driving a manual on the track and as a daily driver. The wagon has been a hoot to drive since I put the staggered VMR's on along with H&R cup kit with their sport springs. Interesting enough the day after I ordered the suspension, the front right strut blew a seal. Crappy Michigan roads!

What am I doing? Well my donor/next project arrived today. Its a salvage 2011 N55 135i with sport package and a manual trans. This is going in the wagon! The damn Euros got them but here in the states no go because wagons are not hip. I thought about doing the s65 swap but then i would "need" the body conversion. This is my summer daily driver and no sense in going overkill.

Diving into the Parts list the trans motor rear diff are an easy straight swap. Drive shafts dont match cause the 335 has a different coupling to the diff than the 328. I have the correct drive shaft en route, it's a standard E90 335i manual trans.Exhaust is going to be custom for a while because its another $1000 to get a euro dual exit, plus I dont mind the sleeper idea.

Sounds like fun! If you don't mind me asking what was the primary damage on your salvaged donor? Reason I ask is I've been looking at some myself but don't know the "best" type of salvage to pickup. This should be a blast

[gixracer]

Been having fun today getting the n55 ready for lift out.
From what I saw on real OEM it the tank pumps are the same between vehicles. (I will double check again later). The tough part is the mess of plumbing. Front bumper came off with the headlights on and made life easy. The front core had the power steering lines, two radiator tubes, inter cooler, the fan control wiring(one plug) and the AC lines. Sound like a lot but it more messy than anything else. I have the wiring to the chassis all disconnected except for the ground on the left side. Tomorrow I am going to tackle the exhaust removal, heat shield and guibo.

As far as ease, right now the plan is to bring the motor out the top instead of doing the subframe. I have a cherry picker, no lift so dropping the subframe is not feasible.

As far a salvage/donor vehicle, I chose one with minimal damage. Mine was side swipe on the drivers side with door and fender damage. It's all repairable. The 135 WILL have a second life(muhahaha)

[E91 M Sport]

As far a salvage/donor vehicle, I chose one with minimal damage. Mine was side swipe on the drivers side with door and fender damage. It's all repairable. The 135 WILL have a second life(muhahaha)

Right on. Sounds like you got a good donor. The majority I've been seeing are either flood damage, which honestly scares me, or ones with major front end damage, which again, scares me LOL!

[CantCatchMe]

Originally Posted by gixracer

south side of Waterford.

I hope to meet you and your project at a cars and coffee soon. Lingenfelter is a fun event on Saturday mornings if you can make that from 8-11am.

[-zd]

subbed!!!

[B.M.W.]

This is going to be awesome! I was expecting a N55-DCT but this is better.

[gixracer]

wow

I am significantly tired. It was a very long weekend not doing much on the cars, eh just little bit.

The 135 proved to be a bit of a pain in the arse.

When taking out the front bumper I advise to take it out with the lights if your are only trying to the motor because it is less work and lees bolts. the engine was easy because the motor control unit it on the engine unlike the 328(more headache to come later from this. Transmission is pretty standard with the 2 clips on the trans and one for the shift rod to remove get the shifter assembly free.

As usual with removing the exhaust I planned on snapping the bolt from the cat to section one. I was disappointed because only 2 broke. LOL. I remember trying to not break any when I did my 330ci zhp swap and broke all 4. Other than those bolts it was straight forward for the exhaust.

The rear diff/ axles pissed me off. The splines were seized in the hubs!!!!!
I had to take the 6 torx bolts off the diff to the axles then completely remove the hubs, and then press them out. the left side was so bad it stressed my 12 ton press to get it out. If I am lucky the wagon axles will be fine for awhile seeing that they are supposed to match up the large diff housing like the 135. Word to the wi$e don't beat on them you will eff up the threads! Save money by spending the hellish time removing the entire hub and pressing them out.

Wagon time.

I copied my experience with the 135 and took the bumper off with headlights to make things easier. There is one extra bolt per side than the 135i but virtually the same. Thinking that the radiator assembly was going to be easier for lack of an inter cooler was a mistake. There was an addition heatsink cooler attached that had 4 extra water connections that had to be removed, messy.

Motor again was straight forward and the engine control is in the right upper pocket with a shit ton of wiring. There are several connectors that had to be divided because the paired up between chassis and engine harness. Just as the 135i there is a trick to pulling the motor up and out. Its easier to remove the right motor mount for clearance on the headers. A tool is also need for the front hoist connection. There is a threaded hole that has the same pitch as the tow hook.........? WTF. The tow hook does engage enough thread so I shaved one of mine to get it in.

The exhaust was simple, snapped all 4 head to section 1s this time, corrosion is a bitch up north here. so far i Have only remove the driveshaft without tackling the differential today.

One thing that has been interesting is that the engine bays are almosy identical. I swapped the ac line that wraps around the back because the the ac pump is on the left side of the n55 vs the right on the n52. Power steering lines were swap due to the different position and dirrection thta they meet up on the cooling support. Only one coolant line need to be swapped.

I had enough time to put the n55 and trans into its new home tonight!!!!

Here are some pics and if you have any other pic requests I have quite a few as I have been taking many as I go.

[Eagle1oh7]

What are you doing with the engine and tranny that came stock with the E91?

[rothwem]

Cool project! How much were you able to pick up the wrecked 135i for?

Were the subframes/engine cradles the same between the two cars?

[gixracer]

Originally Posted by Eagle1oh7

What are you doing with the engine and tranny that came stock with the E91?

I will be putting up for sale next week after everything gets sorted.

Cool project! How much were you able to pick up the wrecked 135i for?

Were the subframes/engine cradles the same between the two cars?

The front and rear subframes are identical. The engine bays are the exact same dimensions and the strut towers are the same distance apart. If you do a bunch of searching you will notice that the part interchangeability is huge. It kind of why I got a 135i. they are cheaper than the 3 series and for my project after the wagon there will be some more fun. Wont be the first, but I plan on doing the 1m clone with a s65 in the long term, $ flow now is tight.

Originally Posted by B.M.W.

This is going to be awesome! I was expecting a N55-DCT but this is better.

It was a thought, I'm a three pedal kinda guy.

[NYBulldog]

Great thread. Your E91 is Automatic RWD non xDrive?