BMW E39 Manual Conversion (Wiring/Coding Instructions included)

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:
https://www.chasebays.com/products/ch...

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