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1000hp E46 BMW M3 - Von Hollen’s Express

One man’s quest to create the ultimate 2003 M3

Justin Fivella
Apr 4, 2014 SHARE

There are parts of Canada so rural, a diehard gearhead could live his entire life without ever seeing an E46 BMW M3. Hold that thought for a second - never seeing one in person, only in magazines and online!

Such was the case for Kenton von Hollen. He'd never seen one until he actually bought an M3. For all he knew, it could have been a unicorn, but that didn't stop him from believing and buying a 2003 E46 BMW M3 in Imola Red.

2003 BMW m3 BMW CSL carbon fiber front splitter 03 Photo 2/11   |  
HPF turbo kit morphed into a custom, high-compression, 1000hp conversion thanks to Labb22, M&B Cylinder Heads, a Precision turbo and AEM standalone

"I've always been a car guy, having owned a built Z31 300ZX with a big turbo as well as a Duramax diesel truck that made over 1200 lb-ft. But I'd always wanted a European car because they seemed more sophisticated, comfortable and fast but could haul my family," von Hollen said. "I live in a rural province of Canada (Alberta) that's bigger than California yet only has three car dealerships. It's the kind of desolate place where you don't see performance cars too often," he added.

As a result of his geographical location, he'd never laid eyes on a real E46 M3 until the day he bought one.

"I'd never seen one, but based on everything I'd read, I knew it was the car for me," Kenton confirmed. "I can still remember the first time I drove the BMW M3. The handling was out of this world and it was built so well. It was everything I'd hoped for," he added.

2003 BMW m3 interior 05 Photo 3/11   |   1000hp E46 BMW M3 - Von Hollen’s Express

Call it fate, but the Imola coupe was only one hour away from his home, tucked away in another small town off the beaten path. The original owner had only driven the pristine M3 during the summer, and a mere 55000 miles were registered on the clock. "Like most good car stories, I initially wanted to keep it stock. But when I turned to the internet for information, the upgrades ignited from there," Ken said.

What started as as simple fishing expedition into E46 car care and maintenance was transformed into a Horsepower Freaks (HPF) turbo build in no time flat.

"After learning everything I could about the E46 M3 on the forums and in magazines, I decided to look into performance mods, and before long I was dead-set on a turbo kit," Ken said. "Shortly after talking to HPF, I scheduled an appointment and drove the car down to Portland, OR for the install," he added.

2003 BMW m3 apex ARC 8 wheel 08 Photo 4/11   |  
Six-piston Brembos were an early upgrade after the stock brakes melted on some high-speed runs

Two short months after buying the 2003 BMW M3, he was about to embark on a journey that would begin with a Stage 2 turbo kit. Five days after delivering the car at HPF, it was making 600whp with methanol injection and 110-octane leaded fuel.

As luck would have it, on his long drive home, von Hollen cooked two pistons in the motor. The loss of compression was traced back to a faulty boost controller and a malfunctioning fuel pump.

Depressed by his bad fortune, von Hollen was unwilling to admit defeat and wasted little time having M&B Cylinder Heads build him a low-compression short block. When run on the same 110/meth combo, it made 680whp with an extra 100 lb-ft of torque compared to when the bottom-end was stock.

2003 BMW m3 BMW CSL trunk 07 Photo 5/11   |   1000hp E46 BMW M3 - Von Hollen’s Express

As with many parts of this build, bad luck was lurking around the corner. This time it metamorphosed as a rogue turbo that would grenade his exhaust system.

"The day I got the built-motor back, the exhaust wheel on the turbo sheared off and destroyed the exhaust system and several other components. Thankfully, the debris went downstream and not into the motor," he added.

Learning to look for the positive is an essential trait if you're going to stick with a build of this caliber. So a replacement 67mm turbo was the quick fix, but Ken was now hell-bent on perfection, and the thought of another failed turbo led him to a dual-ball bearing Precision 7168 turbo with billet wheel that kicked the boost to new levels.

How much? Try 620whp on pump gas and 800whp with race gas and meth.

2003 BMW m3 AEM wideband and boost gauge displays 06 Photo 6/11   |  
AEM wideband and boost gauge displays concealed in rearview mirror

AEM

In this form, our Canadian friend was able to amass more than 20,000 miles driving throughout Canada, cruising down to California, and even hitting track days and Shift S3ctor's half-mile races.

"I took the car everywhere, from airfield events to the drag strip and even road courses. Naturally, I turned down the boost for the latter, but it was a ton of fun and I soon got hooked on track days," he said.

Like all gearheads, enough is never enough, so von Hollen wisely chose to upgrade the M3 fuel system next. "I upgraded to PTFE lines, a Radium multi-pump surge tank, twin Walbro 400 E85 pumps, a Fuel Lab filter and pressure regulator along with a Radium rail and Injector Dynamics ID2000 injectors," he said.

The fuel upgrades were finished the night before Shift S3ctor 3, where the car again threw down 800whp, but this time on ethanol rather than the race gas/methanol combo he'd been previously using. Fresh from the dyno, the M3 claimed the title of "Fastest BMW" with a speed of 178mph.

As you'd guess, Ken was just getting started. His next modification would ultimately become one of his favorites: the plug-n-play AEM Infinity standalone engine management system. "The Infinity opened a lot of tuning doors because it allowed us to control every OEM feature, even the Vanos. We could also tune for different fuels and it helped increase power throughout the rev band. It even made it more drivable!" von Hollen said.

Along with the AEM Infinity, a flex-fuel sensor and fuel pressure sensor were added to take advantage of the standalone's ability to switch maps. "With the standalone and sensors I can run whatever concentration of ethanol I want without having to drain the tank. It's brilliant!" von Hollen exclaimed.

2003 BMW m3 apex ARC 8 wheels 04 Photo 7/11   |   1000hp E46 BMW M3 - Von Hollen’s Express

The addition of the AEM ECU kicked power past 900whp and 700 lb-ft on E90 ethanol, or 680whp on pump gas.

As a testbed for AEM and many other parts, the M3 has withstood more than 250 dyno pulls, thousands of street miles, and plenty of full-throttle track outings. Like all good things though, it eventually came to an end when the head gasket blew.

Lab22

As he'd done before, Ken took a bad situation and turned it around, deciding to build a high-compression motor. In fact, the team at Lab22 removed the old motor and installed its new high-comp replacement in less than a day.

"The Lab22 guys were phenomenal and crucial to the car, both from tuning and tweaking, to the installation of the motor. They also designed the turbo system upgrades. I've got nothing but good things to say about them," Kenton said.

2003 BMW m3 black grilles 11 Photo 8/11   |  
Black grilles, FMIC and carbon splitters aren’t really enough to indicate this car could eat you alive

With some additional cylinder head work to the new 11.5:1 motor, it easily made 925whp on E75 and 25psi boost pressure just days before Shift S3ctor 4. Although they didn't increase the boost until the event, the same combination in another M3 made 1040hp at the wheels on E90 ethanol with more boost.

"The car is so docile but it absolutely flies. It's so fast that it's genuinely hard to describe. Thank goodness I upgraded the brakes early on when the first turbo setup overcooked the stock brakes following some high-speed pulls. That was scary, to say the least," Kenton said.

His binders of choice are six-piston Brembo monoblock calipers up front with 355mm rotors, while a four-piston/345mm combination was fitted in the rear.

For suspension, TCKline dual adjustable coilovers and camber plates plus Powerflex bushings keep the M3 pointed straight. And when it came to putting the power down, von Hollen has been ecstatic with the sticky Toyo R888 tires. Apparently, they hooked up so well, the rear subframe had to be reinforced. Extra precautions were taken with Level 5 axles from Driveshaft Shop as well as an OS Giken R3C triple-disc clutch and lightweight flywheel to turn all that power in into forward motion.

2003 BMW m3 JL XD700 amp 09 Photo 9/11   |   1000hp E46 BMW M3 - Von Hollen’s Express

"I've got a 40% reduced short shifter with race bearings from Autosolutions. It's one of my favorite mods because it transformed the shifting and I'm reminded of it every time I change gear," von Hollen said.

As with its mechanical upgrades, even the cosmetic modifications are hard to spot. "I wanted more tire for better traction, so had the rear fenders widened 0.8" on either side. They retain the stock appearance, so you have to look hard to notice them," Ken said.

Easier to spot are the black kidney- and hood grilles, along with the smoked LED tail lights, corners and the CSL trunk lid.

2003 BMW m3 JL audi 10W3V3 subwoofer 10 Photo 10/11   |  
The car carries a significant sound system but it uses quick-release connectors for track-side removal

Inside, you'll find more subtle touches and a significant stereo, but once again, it's not exactly the norm. "I wanted a killer stereo but needed it to be easily removable for the track, so it utilizes a quick-connect system that allows me to remove everything in 5min," Ken told us.

Some might wonder why you'd fit a stereo in a purpose-built car like this, but Kenton had it nailed: "I've owned the car almost three years and, despite all the motor problems, I've driven more than 35000 miles. I just can't get enough of it. At the end of the day, I just want to drive it and enjoy every mile."

2003 BMW m3 lab22 intake manifold 02 Photo 11/11   |   1000hp E46 BMW M3 - Von Hollen’s Express

Tech Spec
2003 BMW M3

Kenton Von Hollen
Alberta, Canada
Oil Field Engineer

Engine
3.2L straight-six 24v S54 motor with M&B Cylinder Heads and Lab22 built motor with 11.5:1 Wiseco pistons, Crower rods, heavy-duty wrist pins, balanced crank, M&B head, Supertech valve springs, Dr Vanos rebuilt Vanos with cryogenically-treated exhaust hub, Steed Speed CNC'ed exhaust manifold, HPF scavenge oil system, Radium catch can, Lab22 black anodized FMIC, intake manifold and pipe, 71mm Precision PT7168 billet turbo, 44mm Tial wastegate, twin HKS SSQV blow-off valves, AEM Infinity engine management, Walbro 255LPH in-tank pump,ID2000cc Injectors, Radium multi-pump surge tank with twin Walbro 400 E85 fuel pumps, PTFE lines and anodized fittings, Flex Fuel ethanol sensor, fuel temp and pressure sensors, Vibra-Technic engine mount

Drivetrain
six-speed manual transmission with OS Giken R3C triple-disc clutch and lightweight flywheel, Autosolutions short shifter with race bushings, ZHP illuminated shift knob, reinforced subframe, Driveshaft Shop Level 5 axles, Vibra-Technic transmission mount

Brakes
Brembo monoblock six-piston calipers, 355mm grooved rotors f, four-piston, 345mm r, Ferodo DS2500 street pads, Cobalt Friction XR1/XR3 track pads

Suspension TCKline dual adjustable coilovers, camber plates, Powerflex subframe and control arm bushings

Wheels & Tires
18x9" ET 35 f, 18x10.5" ET 27 r Apex ARC-8 wheels, 5mm front spacers, 265/35 R18 f, 275/40 R18 r Toyo R888 tires

Exterior
widened rear fenders, BMW CSL trunk, carbon fiber front splitters, painted reflectors, smoked LED turn signals, Depo smoked corners, black hood and kidney grilles

Interior
AEM wideband and boost gauges mounted in rearview mirror, custom pedal covers and clutch stop, LED lighting

Audio/visual
Dynavin D99+ head unit, JL Audio 10W3V3-2 subwoofer and XD700/5 amp, GAS E46 H/K crossover

Thanks
Lab22, John Truong, Ryan Champ, Chris Nguyen, Joey Letcher, M&B Cylinder Heads, Radium Engineering, AEM Performance Electronics, ApexRaceParts, DERMotorsports, German Audio Specialties, Bill Hall Body & Frame, Marcus Olson

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By Justin Fivella
58 Articles

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