So I have been searching around to find some good inexpensive brake rotor and caliper upgrades for my 1992 e36 325i and have found some nice options and wanted to share. Good news, e46 non///M translates to e36 non///M!
(e36 ///M is not the easiest option for non///M e36, req’s hub & spindle swap, although kit available from Turner Motorsports)
Front brake rotor sizes of E46 cars:
M3- 325 x 28 (not a simple bolt on)
330i- 325 x 25 (12.8", 17" wheels req’d)
323i vert & Touring/325i/328i- 300 x 22 (11.8", 16" wheels req’d)
323i coupe/sedan- 286 x 22 (same size as e36)
http://forums.bimmerforums.com/forum/showthread.php?t=1001447
I think this info translates to the xi’s also, I know for sure in the case of the 330’s
If you use 330 rotors, you must use 330 calipers & carriers, and same with 325/328 parts, except that the e36 carrier is probably same as the e46 325/328 carrier (300mm rotor).
This will likely increase bias to the front of the car unless you upgrade the rear also.
My experience with the 330 swap was positive but I noticed that the pedal travels farther down with the larger piston 330 calipers. I’d recommend swapping in the 330 or perhaps M3 master cyl.
Unfortunately, using 330i rotors in the rear would require a swap of the hubs, shoes, and possibly backing plate to retain use of parking/emergency brake, but I read the rear trailing arms can be swapped out if you can find them. I plan on using the e46 325/328 rear 294mm vented rotors to upgrade my car from the 280mm solid as shown in the following link (retains use of parking brake):
This web page shows some pictures of the e46 325/328 brake swap f & r
http://www.zionsvilleautosport.com/store/htm/brakes/index.htm
If you have any good info to add, please do. Use track pads on the track for best results, put fresh clean Dot4 fluid in, preferably Ate blue/200 or better which is availabe from Innovative tuning for $11 a litre.