[burntoutrubber]

After 2 years and a ridiculous amount of trial and error, I finally cleared the last code (knock wood) on my ginormous project, the first (I think) M56b30 ZHP Touring.

Started with a 2003 M56

1. Rebuilt an M54b30 and fitted with M56 valve cover and intake
2. Installed ZHP camshafts
3. Completely swapped the suspension and brakes to 330 m-sport
4. Swapped in an M54 fuel system with a few tweaks to accommodate the M56 intake (I want it to pass visual inspection)
5. Rebuilt and swapped in an 1060-000010 (330) variant 5HP19 auto transmission and rebuilt torque converter

First I tried to just put the rebuilt b30 block in with the SULEV fuel system but couldn't get the tuning to work. Horrific mileage.

Then I swapped the fuel system.

Then the original transmission from the m56 (325 equivalent) blew up - TC spun out and it just failed, so I rebuilt, learning along the way the difference between the 325 and 330 variants of the ZF 5hp19 transmission.

This weekend, I swapped in a ZHP cluster and coded it, then fixed an SAP code (I had pulled the fuse when wiring the new pump and forgot to replace it).

Today was the first day in two years with a car that ran like it should. And now I have one of probably a small number of ZHP Tourings.

If anyone has questions about de-SULEVing, LMK

 

[Oxford3Dirtyi]

Thanks for this post!

As these cars age and out of emissions warranty, I am seeing more and more SULEV's basically being given away on the West Coast.

 

[burntoutrubber]

If you find one with a good body and interior, it is not that hard to do the swap. You could do it in a weekend if you had the parts, especially now that there is a decent guide

 

[Oxford3Dirtyi]

Out of curiosity, which intake manifold gasket set did you use with the M56 intake on the M54B30 head? The green M56 gasket has FPM imprinted on it and is identical shape front and back compared to the M54 gasket. I'm using the M56 intake manifold (and purge valve with DIN adapter to M54 purge line) on my M54B30. Have not started the swap yet.

Green = M56 11617518036
Orange = M54 11611436631

 

[burntoutrubber]

I used the m56 gasket. My understanding is that it is more robust than the m54 (FPM is Viton). that said, my fuel trims are still at 5-6 which is fine, but higher than I would expect with a completely rebuilt engine with new sensors.

Would love to see pictures and parts for your purge line adapter. I just used a hose clamp on the rubber portion of the m54 end after inserting the stainless m56 end into it.

 

[burntoutrubber]

Sweet day!

 

[burntoutrubber]

Coup de grâce:

 

[ElrichMeister]

hmm, this may be a path i will eventually take. Engine is good, i wonder if there would be issues just converting fuel system.

 

[burntoutrubber]

Nope, just use a stock non-m56 tune

 

[Alex323Ci]

interesting project.

so what all does it have that’s M56 now?

and what does this wagon all have that it’s the (zhp) Performance Package?

 

[burntoutrubber]

Intake, throttle, o2 sensors and valve cover are m56
Cams, tune and cluster are ZHP
Suspension and block are 330 (and ZHP)
Interior upper is black (ZHP)
No alcantera or cube trim

 

[docnabimmer]

Intake, throttle, o2 sensors and valve cover are m56
Cams, tune and cluster are ZHP
Suspension and block are 330 (and ZHP)
Interior upper is black (ZHP)
No alcantera or cube trim

This is quite a challenge .good job!!!
May I ask why you didn't swap to manual?

 

[burntoutrubber]

Daughter's car. She really doesn't want stick

 

[Alex323Ci]

Intake, throttle, o2 sensors and valve cover are m56
Cams, tune and cluster are ZHP
Suspension and block are 330 (and ZHP)
Interior upper is black (ZHP)
No alcantera or cube trim

this really is a nice little project by you.
so cam, tune and cluster are zhp.
so if the wideband O2 sensors are SULEV, which exhaust you running? the stock 4 cat SULEV or a 2 cat M54?

when you say the upper trim is black ZHP trim what do you mean by that. didn’t many wagon 325s have anthracite headliner stock?

 

[burntoutrubber]

2 cat m54 and standard exhaust
I know non-us wagons had black oh shit handles and headliner, but I wasn’t aware it was common here. In any case yes, that is what I have. Recovered.