A transcontinental romance: loving a

[tantumaude]

I've been lurking around these parts long enough; time to introduce myself and my lovely lady.

I'm Mat, live in Oakville, Ontario and have an addiction to storied cars. My first car was a $300 E30, and I've since had a few others. Some may remember me from the E39 section, I did a manual swap on a 540 on jackstands a couple of years ago. Anyways, long story short, I sold my C63 Benz in May and was hunting for a new daily as my Italians were complaining about the commute. I looked at all kinds of cars, from the new Alfa Giulia to E39 M5s and many other things in between.

One day, perusing the classifieds, I spotted a short ad about a 540 in Vancouver. Seeing a blue E34, I thought, "hey, it's like a bigger E30!" and called the seller. Another long story, but I flew out two days later and met the seller. It was an Orientblau on Ultramarine 1995 540i/6 with pretty much all the options (including a car phone!). Beautiful original paint and a mint interior belied the 275000 kms it'd traveled since new. OEM clear signals helped too.
I cancelled my return ticket and bought the car along with a set of Mpars on old summers (I bought the car on its original 17" Style 5s with winters, which wouldn't like the trip home). Over the next three days I raced across most of Canada, covering 4400 kms and killing plenty of bugs. Despite some obvious signs of deferred maintenance and some strange issues, I made it home without a hitch with a few hours before I had to go back to work.

Beginning the trip
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https://imgur.com/oNTWMtr
https://imgur.com/oNTWMtr

Halfway through
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https://imgur.com/eO77gqu
https://imgur.com/eO77gqu
https://imgur.com/eO77gqu

Since then, I've decided to make this car into the DD I've always wanted: fast, comfortable, well-equipped and, most of all, a joy to drive. I discovered that it is one of two cars in that colour combination ever made for North America--and the other didn't have nearly the same option loadout. I'm going to add a few more things.
First things first, the car wandered all over the road, had a horrible clunk when hitting bumps with the right front wheel and had a few electrical issues (seat motors, windows, cluster LCD). I ordered a set of Eibach springs and Koni yellows, and off to the hoist! Turns out the front right coil was broken...I probably wouldn't have driven as fast as I did had I known that. No matter!


Immediate maintenance

A full suspension and steering refresh was needed, so I did that at the same time. The broken foglight lens and windshield were replaced too, and we resealed the engine (valve colver gaskets, valley pan, water pump, hoses, etc.)
As the summer wore on, I fell more and more in love with this car. I added a couple of bits and bobs to make it more liveable (and with toys to match my previous DDs). A CD43 with bluetooth came first, then a repair of all the worn bowden cables in both seats, added lumbar support (difficult on sport seats that don't have the harness prewired), and also rebuilt the headlights with Morimoto HID projectors (like a night and day change--literally). New three-spoke airbag wheel and ZHP knob too for his pleasure.

In mid-August I booked the car in to repair what rust there was. Bottom of all four doors, and a bit around the gas tank filler flap opening. Done in a week and looking quite good, time will tell whether it was a good job. Only problem is that I ordered the regular door bottom mouldings, not realising that I have the Mtech skirts as my car is a 1995. Correct ones are sitting at the border waiting for me to have the time to pick them up.

Last month, my right rear door decided that it didn't want to unlock any more. No amount of tugging on the popper or pulling the handle would change that. One day, while visiting an old friend about 500 kms away, it opened! Two new window regulators and actuator installed.
Went back to the factory-installed staggered Style 5s for winter. The rear tires are from 2004 and needed replacing, but nobody in Canada stocks a 255/40/17 winter tire, so I bought a set of square E39 style 5s and some new winter boots.

Here we are!
https://imgur.com/43ghHZP
https://imgur.com/43ghHZP
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Most importantly, in July I'd bought a 1988 750iL. I parted what I wanted, made my money back, and kept the engine and, of course, the 3.15 LSD. In mid-September I got the diff back from the rebuilders (it needed almost nothing!) and put it in.

What a change! The car pulls almost as well as my old E39 540i with the 3.15 and a manual swap and a couple of bolt-ons. This one has a Dinan airbox (lol) and tune, and an ignition refresh certainly woke it up, but we have a ways to go until my C63-spoiled right foot's appetite is sated...

...Which brings us to last weekend. I bought a S62 for not much money and missing a few bits (intake). Stay tuned for more fix-logging and an eventual build. Lots of parts are incoming this winter as I fly down south and can bring things back every few weeks.

TL;DR young silly guy spends money on a 540/6, drives it back across Canada, fixes a bunch of stuff and has a wildly ambitious plan for more power. Also is quite enamored with said car. More to follow.

[Siebenthal]

Hey!

Wow, I love the colour on your car! it looks amazing! Thanks for writing this thread - its motivating me to continue working on my touring!

subbed!

[moroza]

I didn't know Ultramarine was available on later cars. Blue sport seats, eh?

I've not driven in the prairie provinces, but I too had an adventure racing across Canada (https://www.bimmerforums.com/forum/showthread.php?1486364-E34-in-the-Arctic-(56k-no-way)). The Stewart-Cassiar highway (BC-37) remains my all-time favorite road, perhaps tied with the San Mateo bridge. I imagine in rural parts of SK and MB, the car had a chance to stretch its legs? How far did they stretch?

[tantumaude]

Hey!

Wow, I love the colour on your car! it looks amazing! Thanks for writing this thread - its motivating me to continue working on my touring!

subbed!


Thanks! I think these are some of the best cars BMW ever made, and are definitely worth a lot of work with the rewards they give an attentive owner and driver.


I didn't know Ultramarine was available on later cars. Blue sport seats, eh?

I've not driven in the prairie provinces, but I too had an adventure racing across Canada (https://www.bimmerforums.com/forum/showthread.php?1486364-E34-in-the-Arctic-(56k-no-way)). The Stewart-Cassiar highway (BC-37) remains my all-time favorite road, perhaps tied with the San Mateo bridge. I imagine in rural parts of SK and MB, the car had a chance to stretch its legs? How far did they stretch?


Yeah, it's pretty cool. I was a bit concerned that it would be a smurf when I booked the flight, but it truly looks amazing. I daresay the blue leather must be treated differently, there is hardly any wear on the driver's seat at all.

I read your thread the night before my departure. Needless to say, it's quite inspiring (and much more impressive) than mine--I dream of following your path one day.

I'll tell you how far they stretched once the statute of limitation expires, but I can confirm that the Dinan chip does remove the speed limiter and the stock 2.93 diff allows for a good clip at 4800 rpm. BC has by far the best roads in Canada, but Alberta was actually the quietest and allowed for higher speeds--but I wouldn't have gone over half what I did knowing about the broken coil spring! I just wish I'd had more than three days in which to make it back, so that I could have taken the time to really enjoy the scenery.

[moroza]

BC has good roads but there's more garbage on them than one would expect; I got a fat ticket 40km outside of Hudson's Hope.

[tantumaude]

BC has good roads but there's more garbage on them than one would expect; I got a fat ticket 40km outside of Hudson's Hope.

Guess I got lucky in that regard, I think I saw all of three cops on the whole trip. My average speed from start to finish was 109 kph, including all the stops and time spent in jams (Ontario mostly, especially one 60 km section where I was stuck behind a tractor going 40 kph).

As for the car, I ordered a 750iL master cylinder to accompany my rebuilt E31 brembos, and also everything needed to rebuild the S62 (WPC bearings especially). Just need to decide which VANOS service kit to use, Beisan or Dr Vanos.

I'll try to figure out why my driver's seat only has heating on the backrest and not the base, along with the strange cluster issues (gauges all work, as do LCD pixels, but the LCD displays all kinds of gibberish)

[Strife]

BC has good roads but there's more garbage on them than one would expect; I got a fat ticket 40km outside of Hudson's Hope.

MB and ON are known to have an absurd amount of police along the highways. Depending on the specific ones, if he took HWY 1 east of Winnipeg to the ON border that would of been his safest opening in MB, other than that there really is no safe place to open up. and rural police are privatized and funded well in Ontario.

[Strife]

By the way awesome story and congrats on the car! I live in Eastern MB near Falcon Lake and would love to come see that car some time if I'm ever around there, super jealous of the 3.15..... Along with the M-Pars and Style 5's..... All I really have going is black M5 interior conversion, respray and HID's, and BMW warranty replaced short block at end of warranty extension; my Oxford on Parchment HE53 was originally from AZ.

Oh also, prepare to be doing annual rust work on the bottom of those doors since this car will be a daily; those lower door mouldings will always trap moisture, and with the salt we have on the roads in our provinces it doesn't take much to bring it back again, the doors can really only go unattended for multiple years in climates better than ours.

How are the throttle cable bushings? You seem well versed in the highest priorities an e34 needs but those are one thing that can be overlooked easily, they don't get a lot of mention, making sure the cable is adjusted properly with the billet bushing alternatives on ebay make a world of difference in throttle response.... Until lightweight flywheel time if you choose to do so.

[ShapeShifter]

Cool car, post a few pic of the interior.

Enjoy!

[tantumaude]

By the way awesome story and congrats on the car! I live in Eastern MB near Falcon Lake and would love to come see that car some time if I'm ever around there, super jealous of the 3.15..... Along with the M-Pars and Style 5's..... All I really have going is black M5 interior conversion, respray and HID's, and BMW warranty replaced short block at end of warranty extension; my Oxford on Parchment HE53 was originally from AZ.

Oh also, prepare to be doing annual rust work on the bottom of those doors since this car will be a daily; those lower door mouldings will always trap moisture, and with the salt we have on the roads in our provinces it doesn't take much to bring it back again, the doors can really only go unattended for multiple years in climates better than ours.

How are the throttle cable bushings? You seem well versed in the highest priorities an e34 needs but those are one thing that can be overlooked easily, they don't get a lot of mention, making sure the cable is adjusted properly with the billet bushing alternatives on ebay make a world of difference in throttle response.... Until lightweight flywheel time if you choose to do so.

Thanks! I did not think of check the bushings beyond the normal inspection--I tightened up the cable and made sure there wasn't any resistance to closing. I'll have a look at them when I come home. I've got a pretty good guarantee on the doors, but I'll keep it in mind. Salt is indeed a huge problem, but I think between my frequent washes, garage keeping and, let's be honest, using other cars on days just before and after storms, I'll be doing the best I can. I'd love to have you come and see it!


Cool car, post a few pic of the interior.

Enjoy!

Thank you, I'll do that very soon.




I picked up a few goodies this week while I'm in Florida: brand new steering box, OEM first aid kit (thanks junkyard!), some BavAuto rubber floor mats, and a spare LCD for the cluster. We'll see if I can figure it out soon. Started tearing down the S62 as well, pics to follow. I've got to find a place that can tweak my S62 DME (dyno mode, EWS, postcat 02 and SAP delete) and build me a harness adapter (I don't have the patience for wiring). Any suggestions are appreciated!

[tantumaude]

Got a few things done yesterday. Installed 3 of 4 door handle gaskets (thanks Shogun!) I broke the fourth handle surround as I was removing it, so I have to get one before I can finish the job. It looks pretty horrid all taped up! Makes a nice difference to the car, it's been bothering me since I got it.

Old:
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New:
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Also put on some clear front sidemarkers. Not 100% sure I like these...
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[tantumaude]

Got a brand new steering box installed today. What a world of difference. No play and no sudden changes of direction, joy!

[moroza]

Brand new? I didn't realize they were still available at all. Did the old one run out of adjustment?

[tantumaude]

Brand new? I didn't realize they were still available at all. Did the old one run out of adjustment?

Yup, apparently I got the last one available. :) The old one was a bit of a mess, which I'm not too surprised to see with almost 300k kms.

[bigsixe34]

Wow blue/blue! Very interesting, I too want to see an interior shot.
I can't even imagine how much better the car must feel with a brand new steering box. One thing that's guaranteed - if this board had caught wind of there being a new one in Germany somewhere, it would have sold years ago :p

[moroza]

I'm sure it's an improvement over a used box, but even period reviews of brand-new E34s complained about the steering. Rack >> box.

[ericsyzf]

Got a brand new steering box installed today. What a world of difference. No play and no sudden changes of direction, joy!

Did you find an actual new box or is a rebuild?

[tantumaude]

I'm sure it's an improvement over a used box, but even period reviews of brand-new E34s complained about the steering. Rack >> box.

Agreed on both counts. My biggest complaint is about how slow it is. I wish there's been a quicker box available (m5 boxes don't seem to interface well with no servotronic)


Did you find an actual new box or is a rebuild?

Brand spankin' new from ZF :)



In other news, I got the car off the hoist and took a couple of pics of the inside. Not bad for 22 years and 280k! Admire the car phone!

[tantumaude]

Just came back from Florida again, into a snowstorm. Got some more S62 parts (gaskets, clutch, MAFs) and a set of E32 door handle trims (metal, yay!)

On my drive home

[tantumaude]

Got the last door handle gasket installed and went for a drive. :) Heckblende arrived yesterday.


I've now bought the most important part for the S62 swap:
https://i.ebayimg.com/images/g/CUQAAOSwa39U0ta7/s-l300.jpg

I have a strange sense of humour. Yes, I know it's for an E39. Couldn't find an E34 one.

[WordMan]

Got the last door handle gasket installed and went for a drive. :) Heckblende arrived yesterday.


I've now bought the most important part for the S62 swap:
https://i.ebayimg.com/images/g/CUQAAOSwa39U0ta7/s-l300.jpg

I have a strange sense of humour. Yes, I know it's for an E39. Couldn't find an E34 one.

Love it!

[tantumaude]

It's been a quiet few weeks due to some crazy cold and lots of work. Did the bearings in the S62. Also had the coolant tank break in the E34--that was interesting. The resultant spray shorted out one of my HID assemblies, which I now have to diagnose. Ballast or relay...what joy.

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Anyways, ordered about plenty of parts to finish the S62 refresh and clean up a few things...shifter bushes, brake pedal switch, etc. Unfortunately the dreaded steering play has returned, even with the new linkage, steering box and bushes. Really at a loss now.

Changed the cluster LCD and finally fixed the messed up (read missing) driver's door brake. Added a Koala Motorsport reinforcement plate :)
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Before
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After

Also deciding what wheel setup to run next summer. 17" staggered style 5s, or 18" mpars? Either set would need new tires, not sure which I prefer. Thoughts?

[moroza]

I'd go for 17's myself. You're more likely to notice the difference in comfort (taller sidewall and less unsprung weight) than performance given the same tire. MPars do look great though. And at least you're not asking about 20's :rolleyes

As for your steering play... did you adjust the box? What do you mean by "new linkage", or "full suspension and steering refresh"? 2x tierods, 4x control arms, 2x strut mounts, center link, idler arm bushing, pitman arm secure to steerbox, steerbox worm/sector lash, steerbox sector shaft play (is that even adjustable on ours? It made a big difference on an old Mazda I worked on), 2x (IIRC?) steering column u-joints, steering column rubber coupler, steering column telescoping nut... I can think of more but unlikely to cause steering play without very noticable other effects (thrust arm crossmember, wheel bearings, steering column bearings...)

[tantumaude]

Thanks. I'm worried that I can only go 255 wide on the rears in 17". Might be an issue with the S62, even though I have the LSD already. I loved the Mpars, but after putting 17" winters and enjoying the improved ride, I'm really torn.

As for the play, it's a brand new box (about 200 kms on it). It was fine at first, but yesterday the play started again. Everything you listed was done in August with Lemforder parts, except for the column stuff.

[tantumaude]

The bearings had seen better days, changing them was a good move. Lots of crud on the inside as well, I'll have to clean that.
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Going down south next week, I should be able to bring back my wiring harness, DME, and most of the rest of what I need to do the swap. Got my gearbox, flywheel and clutch too. I plan to do the installation in April or May once it's warm again.


Also ordered an E34 M5 cluster, so that I have an accurate redline and the oil temp gauge. How do I reprogram it to work with the V8? I'll also have a CANBUS controller on the new harness.

[tantumaude]

I hate winter, can hardly get any work done. Anyways, ordered some guide and chain parts for the S62, as I found some pieces while rotating the engine on the stand.

My heater valve failed last week (one end broke), I hate having to deal with cooling issues as it makes a huge mess every time. The door reinforcement plate seems to be moving as well, I think I'll have to weld it to the door.
As for the steering play, my mechanic suspects the steering column splines are worn--there is no play between the wheels and bottom of steering shaft. The wandering seems to be caused by too little caster. Sadly it's not adjustable, so I'm wondering if the drag link adjustment procedure would help.


Therefore, I cheered myself up by ordering a M5 plate surround and some funny decals for my E31 brembos. Stay tuned for pics of that. Also got the rare rear oem PDC kit, but not sure if I want it. The PDC in my E91 drives me nuts.

[sugaki]

Love the unique color combo (never seen a latter-model ultramarine either), I've always fantasized about gutting a BMW phone and making it compatible as a headset... not engineering-minded enough for that though.

Yeah those clear side parking lights are a hard contrast to the dark blue and black trim--think the Euro trim would look best with those lights deleted.

[tantumaude]

Love the unique color combo (never seen a latter-model ultramarine either), I've always fantasized about gutting a BMW phone and making it compatible as a headset... not engineering-minded enough for that though.

Yeah those clear side parking lights are a hard contrast to the dark blue and black trim--think the Euro trim would look best with those lights deleted.


Thanks! Yeah, I'd love to get the phone working, but I'd probably lose the hands-free capability it has. It would be very cool though.

Thanks for the opinion on the markers. I can't get Euro trim due to regulations here that stipulate we need at least side reflectors. (I've seen it enforced in winter, which is not a bad thing). I think I'll go back to the orange ones.

[Germanas]

Really awesome, any future mods you have in mind?

[tantumaude]

Really awesome, any future mods you have in mind?

Thanks! S62 swap is the big upcoming project. Once that's done, the only other thing I'd like to change about the car is the steering setup...so maybe a rack install. Aside from that I can't think of many other things to change. Suspension is pretty awesome, LSD swap is great, all my electronic add-ons make it as nice as my newer cars.

Only thing left to fix is the bottom part of the driver's seat heater not working and to play with the lighting system to get rid of the DRLs. At that point I think I can say I will have built my perfect car.


Speaking of which, I got the decals for my E31 brembos today!
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Going to try to do the S62 timing chain guides and other engine work in the next few days.

[tantumaude]

Started the guide job today. A lot of sludge in the engine, but cam lobes look good. Unfortunately one of the VANOS board is damaged (two capacitors missing, broken wires), so I need to have those repaired. Guides were a bit worn, nothing catastrophic.

[moroza]

Eww, that sludge does not speak highly of its previous ownership.

Your caster is off? Unless your suspension is very worn, that's a sign of body damage.

[tantumaude]

Eww, that sludge does not speak highly of its previous ownership.

Your caster is off? Unless your suspension is very worn, that's a sign of body damage.

Yeah. OEM spark plugs though, which is either a really good or really bad thing.

As for the caster, that's my alignment guy's theory. The car's never been accidented and has all new front suspension, so we're trying to figure out the wandering.

[moroza]

Is it a hunch, or did the caster actually measure out of spec?

[tantumaude]

Is it a hunch, or did the caster actually measure out of spec?

Hunch. He builds racecars and works on exotics for a living, so I have little reason to doubt that he'd be incorrect. Not saying it's out of spec, but that increasing it would help with the vagueness.

[tantumaude]

In other news, this happened 30 minutes ago:

[moroza]

I'm going to heckle you for the fuel filter location, but mostly :redspot

[tantumaude]

I'm going to heckle you for the fuel filter location, but mostly :redspot


I'd have expected more disapproval of the DME location upside down on the driver's ebox! What about the intake tract just above the exhaust? ;)

[moroza]

Well, that all looks like temporary dangling for initial "does it even work" purposes. At least they belong in the engine bay. I don't like volumes of gasoline hanging out near lots of electronics...

[tantumaude]

I see...yes, it's far from ideal. I'd much rather it sat under the floor as per the E39, but the oem hardline is NLA, and my line making shop has closed, so this will have to do in the short term.


Interestingly, my shifter seems too far back now that everything is bolted up. Yes, it is the right way forward (UUC short), but in fourth it almost hits the rear of the shift surround. Perhaps the E34 and E39 shift arm are different length. Another possibility is that the shift arm link joint at the tranny is a different design (although the E39 one is listed as fitting the E34), part no. 25111222688 (e34) vs 25117580281 (e39)

[moroza]

E34 540iM shifter arms (the horizontal ones) are unique; I'm not surprised the E39 one doesn't work.

[Kingpin025]

Very cool color combo and build.

[tantumaude]

E34 540iM shifter arms (the horizontal ones) are unique; I'm not surprised the E39 one doesn't work.

No, I'm using the E34 arms. The only interchange part I'm using is that which attaches the selector arm to the selector shaft. It's listed as fitting pretty much every BMW since the E30.

[Tristan36]

ive got the same issue with my s52 swap when shifting to 2nd or 4th it smacks the rear of the shift surround let me know what you do to fix yours.

[Creesic]

Give blue sport seats please.
Beautiful car, though. Great find.

[GazM3]

Nice. S62 swapped e34’s are great. U will be very happy when it’s all done.

[tantumaude]

Little update on the S62 swap: I need to relocate the oil filter, there simply is no way to get it to fit around the brake booster, electric fan and rad hose. Also need to make said rad hose, and finish a couple of little odds and ends. Hope to have it buttoned up in the next two weeks.

As for the shifter, I think I'll just spin the shift lever 180 degrees, hopefully that will solve the problem.

[tantumaude]

Moving along nicely, made the oil filter relocation lines yesterday and wired most of the interior stuff. The last big hurdle is making a PS line to go from the E34 steering box to the S62 pump, once that's done I should be able to fill all the fluids and go for a drive. I just can't get to it with the engine in place, struggling quite a bit.

All the exhaust hardware either disintegrated or had to be cut off when I removed the system, so I will be getting a custom catback made as soon as the car is on the road. Can't wait!

[moroza]

custom catback made as soon as the car is on the road. Can't wait!

X-pipe, I hope?

[GazM3]

I’d prob favour a slotted merge rather than an x-pipe personally the longer the slot the better

[tantumaude]

None of the above. The cat sections already have their collectors upstream, so it will simply be a case of routing the twin pipes through a resonator, smaller muffler, and out.

[tantumaude]

Good news! The car started with the S62 for the first time today...had a dying starter and crossed fuel lines to blame.
https://www.youtube.com/watch?v=WIDsui1uOi4

[moroza]

Hurrah! But that video is disappointingly short. Sounds fantastic for about 1 second.

X-pipe would go after the cats. In the E39 M5 it's an H-pipe between the cats and the resonator.

[tantumaude]

Hurrah! But that video is disappointingly short. Sounds fantastic for about 1 second.

X-pipe would go after the cats. In the E39 M5 it's an H-pipe between the cats and the resonator.

Yeah, I'm trying to upload a longer one but youtube is failing me.

Sorry, yes, I misunderstood you. I'll be discussing it with the shop today and make a decision then on the x- h- or straight pipes (with resonator and muffler, but no joint).

[tantumaude]

Exhaust is almost done.
Need to sort out the ASC. I'd like to retain the braking part, but there obviously is no throttle plate anymore. Can it be reprogrammed to work just on that? I only have the fault light currently.

[tantumaude]

Exhaust is finished. A little loud for my taste, but it might grow on me.

Bigger problem is that after a 10min drive, the BRAND NEW E34 M5 coolant tank developed several leaks where the cap neck meets the main body. Of all the things with this swap that could break, it had to be the one thing I have not modded or bodged. Great.

[WordMan]

Did you ever try to make the M5 cluster work?

[tantumaude]

Did you ever try to make the M5 cluster work?

Not yet. My CCM is throwing all sorts of phantom errors, so I've been putting it off until I sort that out. I may just do so this weekend.