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Old 06-19-2023, 09:56 AM
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Wiring for 4.4 or 4.6IS manual transmission conversion

Wanted to share the wiring steps for those who convert a 4.4 or 4.6 to manual. I was grateful to williamx5 for his documentation of several steps with an overall conversion, and found a simpler approach to wiring. Read his good write-up on explaining the different starting circuits pasted below.

Clutch pedal wiring
When you install a factory clutch pedal assembly, which includes clutch master cylinder, the clutch switch module on side of cylinder and pigtail harness (part #61116911072), there are 4 wires on the harness to run:
Pin 1 is ground
Pin 3 is switched power
Look over at the brake pedal and there's a brake light switch (proximity sensor). The purple wire (power) will match the wiring to your clutch switch harness, and same with ground. Doesn't hurt to verify. On a factory 3.0i manual, the clutch and brake module share power from this circuit so it was meant to be!

Pin 2 is a switched ground that needs to be run to the ebox. Clutch pedal resting = continuity to ground, clutch pedal depressed = no continuity. I found running the out of grommet carrying clutch reservoir hose, along backside of firewire, and over to ebox was a good run.

The DME needs to be converted for a manual transmission.

So Pin 2 goes into x00004 connector (40pin) at pin 23 on the DME. You can see in wiring diagram for 4.6IS factory that its unused, but in a 540i its the clutch switch circuit.

Lastly, Pin 4 - you don't even need to extend the wire...it goes to the EWS which is in the footwell where the pedal assembly is. Clutch pedal resting = 9v, clutch pedal depressed = 12v.

On the EWS, de-pin 6 (formerly the auto trans position sensor). Replace pin 6 with your wire coming over from pin 4 of the clutch module.

Reverse light
Straight from williamx5: 2 wires from gearbox sensor into the ebox. Ground one of those wires to chassis, and the other wire goes into x00002 connector (24pin) at pin 2 on the DME. Then, one new wire from DME x00004 connector (40pin) at pin 19 needs to go to IKE (the gauge cluster) blue connector (26 pin) and into pin 25.

Note: one new wire for the clutch and one new wire for the reverse signal, for a total of two, need to be run between ebox and footwell/dash area. Obviously, its easiest to run to them together so plan accordingly and going out of the ebox through one of the bellows, along the wiper reinforce (avoid moving arms), and down into clutch master cylinder feed line grommet was a good path hidden from view.

Hope that helps.

williamx5's post explaining the different starting circuits. I opted to use wiring methodology above instead of following his way but I'd imagine both would work:
https://xoutpost.com/1109964-post124.html

Last edited by jbfrancis3; 07-16-2023 at 09:56 AM.
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