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Thread: Project Broomhilde

  1. #1
    Join Date
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    Project Broomhilde

    So just to keep a record of these things and find answers and help others I'm going to keep it all in this thread. For a while there it was "whats wrong with it today?". So this is my first BMW or German car I've owned. I started on the forums looking for all the common issues and how much was DIY and then decided to start looking for one in decent shape. I ended up finding Broomhilde, that's what I named her since she's a big Bavarian bitch, in New York city. So I flew up there to go check it out and after a very long and frustrating day I left NY around 8pm to start the 8 hour drive back to NC. I'll just say there was a lot of bonding on that all night trip home.


    She's a Black May 2001 540i/6. As the shop I took her too after I got back home said it's a typical leaky BMW. This was a German car specialty indy but the estimate he gave me sounded like more than the dealer would charge. He told me $3000 for the valve cover job! Ha so I took his list of problems and I've been doing my research since. Now I'm just going to list off everything I've done since I got it.

    Topped off engine oil and power steering fluid since both are leaking
    Replaced air filter with K&N drop in unit
    Washed, clay barred and waxed exterior
    Completely cleaned interior and conditioned the leather
    Replaced broken center vent
    Installed Dynavin N6 and rearview camera link here
    Replaced passenger side front and rear tires with Conti DWS. They had bulging sidewalls.


    Now for the leaks and old pieces that I'm going to replace very soon.
    E60 "short shifter", ZHP knob, and shifter rebuild kit from ECS (thanks santa)
    Valve cover gaskets with new bolts/seals Hopefully I can find the new OEM viton gaskets
    Upper timing cover gaskets
    Powder coat valve cover gaskets. Hopefully the same silver thats in the engine bay already or flat black
    Power steering reservoir, 2 hoses, and fluid flush
    Cam sensor gasket and seals (not the sensor)
    Timing chain tensioner
    Fuel tank breather valve / purge valve for the P0443 code I'm getting intermittently
    New spark plugs. I decided on the BKR6EK
    Das spark plug boots
    New transmission fluid. Going with Royal Purple Syncromax
    New differential fluid. Again Royal Purple Max Gear oil
    Rear sway bar end link. The right side is snapped off
    Maybe the 16.5mm M5 rear sway bar since I'm down there, thats my excuse anyway.
    Oil change after everything is done


    The "one day" list
    DDM front and rear M5 bumper
    DDM 3000k HID for the fog lights
    New muffler that doesn't lose low end power link here
    Clutch delay valve delete
    Euro armrest with storage
    New master and spare keys


    Hopefully these lists get done and new ones get made in the coming months. I'm new to the E39 and German cars all together so I will listen to any advice anyone feels like offering! Thank you in advance for all the help I'll get in this thread!
    Last edited by Arkum; 12-28-2014 at 02:54 PM. Reason: link

  2. #2
    Join Date
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    1997 BMW 540i 6 speed
    Brynhildr, as in valkyrie?

    Get a copy of the Bentley E39 service manual and a good scan tool.
    Last edited by edjack; 12-28-2014 at 04:08 PM.


    Ed in San Jose '97 540i 6 speed aspensilber over aubergine leather. Build date 3/97. Golden Gate Chapter BMW CCA Nr 62319.

  3. #3
    Join Date
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    Oh, didn't know that you too live in Raleigh.



  4. #4
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    No not from valkyrie. Its from a movie. I got the Bentley manuals for christmas so I'm good to go!

    Quote Originally Posted by edjack View Post
    Brynhildr, as in valkyrie?

    Get a copy of the Bentley E39 service manual and a good scan tool.
    Yea I'm in Raleigh. What part are you in?

    Quote Originally Posted by auaq View Post
    Oh, didn't know that you too live in Raleigh.

  5. #5
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    Close by WakeMed Hospital on New Bern Ave off of exit 13 on I440.



  6. #6
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    And there goes $1000. Thanks ECS!

  7. #7
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    Does anyone know the name of the silver thats on the engine cover? I'm powder coating the valve covers and I want to do it in that silver if I can find it. So far the powder coaters can't find a match so I might just do black

  8. #8
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    2010 E61 535i Xdrive
    I have no idea what the original color was, mine were so nasty. Nice car and good luck with the project. I did mine in wrinkle black fwiw.

  9. #9
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    Todays problem is brought to you by the coolant system.... "CHECK COOLANT" message and steam coming from the hood followed by a puddle underneath. There seems to be some splatter on the water pump and its brown rust colored. There seems to be spray as far as the power steering reservoir as well. I'm gonna try and get a better look at it tomorrow when its light out. I'm about to do the VC gaskets and a bunch of other things next week so I might as well mess with this then.

    For adding water to the coolant I'm looking for distilled water correct?

  10. #10
    JimLev's Avatar
    JimLev is offline Artifically Aspirated Moderator
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    Brown rusty coolant? You should probably drain all of it out, flush it out, and then a 50/50 refill with coolant and distilled water.
    Last edited by JimLev; 01-27-2015 at 09:43 PM.

  11. #11
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    Angry

    Yea that's what I was thinking. Looking at it again today after I drove to work it seems like it might be leaking out of the top of the water pump where a sensor is. On the drive the temp would spike to around 245 for 30 seconds or so then back down to 225 or so for a minute or two then back up again. Doing that the whole ride to work. I'm thinking about ordering the coolant system refresh kit from ECS Tuning (pump thermostat hoses and fan iirc)
    Last edited by Arkum; 01-28-2015 at 01:24 PM.

  12. #12
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    A LOT has happened since the last post. Im just gonna go over today for now.

    Today I removed a leaking power steering hose that runs from the steering box to the oil cooler (part number
    32411094205). It was a nightmare at first but once I found out how to find the other end it wasn't too bad. You need at least 16" of extensions for a ratchet, a U-joint, and a 22mm socket. The bolt is about 6 inches under the valve cover. Mine was covered in dirt and grime and just blended in with everything else. I couldn't find it until I stuck my hand back there and just felt around for it. Its on the drivers side near the 3rd bolt back in reference to the valve cover bolts. The ratchet setup that worked for me was the 22mm socket with a 1/2 to 3/8 converter then the U-joint then a 3" + 6" + 10" extensions. Also don't forget about the 8mm screw that holds the hose to the chassis underneath the car.





    Last edited by Arkum; 02-21-2015 at 10:56 PM.

  13. #13
    Join Date
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    E60 "short shifter", ZHP knob, and shifter rebuild kit from ECS (thanks santa)
    Valve cover gaskets with new bolts/seals Hopefully I can find the new OEM viton gaskets
    Upper timing cover gaskets
    Powder coat valve cover gaskets. Hopefully the same silver thats in the engine bay already or flat black
    Power steering reservoir, 2 hoses, and fluid flush
    Cam sensor gasket and seals (not the sensor)
    Timing chain tensioner
    Fuel tank breather valve / purge valve for the P0443 code I'm getting intermittently
    New spark plugs. I decided on the BKR6EK
    Das spark plug boots
    New transmission fluid. Going with Royal Purple Syncromax
    New differential fluid. Again Royal Purple Max Gear oil
    Rear sway bar end link. The right side is snapped off
    16.5mm M5 rear sway bar since I'm down there, thats my excuse anyway.
    Oil change after everything is done
    All of those are done now in addition to:
    New Water pump and thermostat
    New upper, lower, and expansion tank hose
    New o-ring for the aux fan temperature sensor in the lower radiator hose (leaked when I put it back together) part 13621743299


    Now all I'm waiting for is the power steering oil cooler return line (steering box --> oil cooler) part 32411094205... Fill and bleed it and I'll be DONE! I hope...
    Last edited by Arkum; 02-22-2015 at 01:53 PM.

  14. #14
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    Quote Originally Posted by Arkum View Post


    I have to do this hose eventually... And I really don't want too!

    Great Progress so far.
    2003 BMW 540i [Sterling Gray / Gray]
    [Msport] [Mods from A-Z] [Two-Tone Interior]

    Stuff For Sale :
    All types of E39 OEM Used HVAC Buttons
    Other E39 Parts, see my ebay! [Click]



  15. #15
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    Friday the bottom of the coolant reservoir gave out and dumped all the fluid so I had to play parking lot mechanic.

    New coolant reservoir and BMW coolant (again) at 134,xxx miles $151

  16. #16
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    Some pics from last month that I finally got uploaded







    Last edited by Arkum; 03-31-2015 at 12:27 PM. Reason: pics

  17. #17
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    They looked really nice in person too.
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  18. #18
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    How did you clean the valve cover? Looks really nice!

  19. #19
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    Looking good!



  20. #20
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    I took the valve covers to Top Coat a local powder coating company. They sand blasted and chemical dipped them before powder coating them. I would recommend them to anyone in the area.

    I did also clean the inside of the valve covers again to make sure there was no leftover debris from the sand blasting.

  21. #21
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    Just make sure to bake them before powdercoat - between 200 and 250 degrees - to release the oils from the Mg. Maybe do it twice, cleaning between each time, and only then add powdercoat. Otherwise the PC will flake off again over time.
    2003 Ferrari Red M3 3.5L wagon // 2011 Montego Blue tri-turbo 335d wagon
    2012 Deep Sea Blue X5d // 2003 Orient Blue 330i wagon
    In progress/For Sale: 2003 Alpine White M3/ZHP wagon // 2003 Japan Red M3/ZHP wagon

  22. #22
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    I was just about to post this^

  23. #23
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    Got a euro arm rest with storage on ebay and installed that today. The tray won't click into place but it still stays. I'll keep messing with it.
    Attached Images Attached Images

  24. #24
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    Replaced the old blue and "white" vacuum lines with some high temp silicone lines.


    Added some bungee cord to the trunk cubby to hold stuff in there. I used 1/8th cord and a 1/8th drill bit with some washers to hold them in place. Cost under $3 compared to the euro version thats $90!
    Attached Images Attached Images

  25. #25
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