This is the story of my 2003 540iT M-sport from when I bought it through now. Maybe someone will find it helpful. It's also a good way for me to keep a journal of what is happening with it on a regular basis.
After a long search, and after realizing that '03 M-sport tourings were very rare, when I saw this clear across the country on BMW's CPO site, I knew I should jump on it despite it not being the color combo I was hoping for. Sapphire Black on sand. It does have every factory option except PDC (what were they thinking leaving that out?!?). It had just under 25,000 miles on the odometer at the time and was a single owner car. I was told the PO curbed the front bumper so they replaced it with a brand new one. The wheels were also refinished.
When I purchased, BMW was having a sale to move out the older E39 CPO cars. The offer was "we'll make your first two payments" so I financed the entire amount and did the shortest term possible so that BMW ended up paying almost $2K of the purchase price. That's pretty good considering it had already lost roughly $25k in value versus MSRP (I have the sticker).
It was located in California so I had a friend who was living there at the time go and check it out and it seemed in good working order so I made an offer, negotiated a bit, and then arranged for shipping from Berkeley to Raleigh in summer of 2006.
Here is what she looked like when I got her home:
Pretty soon after I bought her, Dinan was having a massive 50% off (I think that was it) sale on all parts, so being a track guy, and having a track instructor wife, we found the stock suspension a bit floaty (even though it's a sport suspension) and we jumped on a Dinan Stage 3 suspension plus engine and transmission software. I also added a Conforti CAI to go along with it and of course it needed M5 wheels in 18x9.5 all around and 275/35/18 tires to match the new stance:
One night, we were at our local BMW CCA dinner and a member stood up and asked if anyone had an E39 with sand interior. I said I did. He asked if I was interested in the Euro dash conversion as he was selling his E39 and wanted to find someone who would appreciate it. I said sure, and asked how much he wanted for it, knowing it was probably going to be hundreds of dollars given the parts cost over $1k from BMW new. Long story short, he came to my house and completely installed the kit for $250 including parts and labor. You could say I was thrilled!
The touring was happy for a while in this configuration living along side it's slightly older, but more powerful sibling, my '01 M5:
I then added M5 style side mirrors and carbon fiber roundels plus a Magnaflow muffler:
Some slightly skinnier winter wheels and tires (D-Force EmPower 18x8.5 with Conti DWS) and M5 front calipers and rotors to give her a bit more stopping power to match the wider tires:
The rear hatch stopped working so I found the problem and fixed it - the wire had become cut from the open/close of the hatch over time:
Leaking power steering system (and probably valve cover gaskets too):
Added Umnitza VXX LED for the halos:
Having some funkiness in the rear, I decided to go ahead with rear subframe bushings at around 60-65k miles. Turns out they weren't in such bad condition but at least they're good for another 80k now:
Removal of T-bar up front:
Coming home from dinner one night, I got a coolant light and stopped at the gas station. Turned out she was bleeding all over. Full system replacement commenced around 70-75k with radiator, thermostat, water pump, pulleys, belts, overflow tank, all the hoses, all the sensors, and more:
I got the bug again and wanted to install an S62 so I bought one along with all the parts I'd need to convert the car, but as it turns out I ended up selling those in favor of adding a supercharger instead. Long story and lots of pros/cons later I felt it was the best decision for me at this time.
After selling what was left of the S62 and associated parts, I had some good parts left over: LSD from the M5, driveshafts from a 540/6 and M5, M5 axles, M5 gauge cluster, and M5 steering box. I found the rear suspension and parts of the front were in pretty bad shape, and since my power steering was leaking like mad and getting worse, I decided it was time to pull everything, install the M5 steering box, and refresh the entire suspension. I ended up replacing all the control arms, bearings, rear lower ball joint, and even the front suspension from Dinan to Ground Control. It made a huge difference in comfort and handling and I am thrilled with the change. The steering ratio on the M5 is much more natural and I was able to wire up and code servotronic thanks to geargrinder's great instructions and blackknight530i's help.
Headlights needed adjuster repair:
Replacing front lower grille with open grille for better brake cooling:
M5 gauge cluster and AeroForce Interceptor Scan gauge for monitoring boost, coolant temp, and more:
Now I'm working on the supercharger installation. While I'm in there, valve covers (newly powdercoated in black wrinkle, special thanks to geargrinder for lending me a spare set) are being replaced with gaskets, new spark plugs, new injectors, valley pan gasket, and more. We also have to do a "before" dyno to see how the changes work:
Yeah, the valve cover inner gaskets were leaking horribly - look at all that oil on the coils and in the spark plug valleys:
A while later, all cleaned up and ready to pull the covers:
This is where I'm at as of this morning.
Last edited by Redshift; 03-04-2015 at 08:00 AM.
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
You sir have committed a HORRIBLE CRIME to both humanity and the automotive community! You must hand over your keys immediately as I am here to save you from you and you us from you and all that! As a friend and brother in wheels - I feel it is my duty to bring that car back to No. Cal!!!!
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Give it a minute, see if that ruse worked!![]()
How about...no.
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
Its not red. You lied.
Another FP5241 Creation
Parting out M54 Engine. Intake and all. Cats avail as well. PM ME!
Fine! In that case, I want to pack my touring full of parts and head to your garage - don't need a bed, I can sleep in one of the cars till all the work is done. AND... I want to ride the Ziggle
Have you been hanging out with Brandon? Your pictures look alike. Nice work there man, I am very envious indeed - that wagon went to a very good home. Funny it came from Berkeley. Was that from Weatherford BMW? I know a good guy that works there who also has a 540iT. Imagine that, only 15 miles or so away from me.
So, how many garage facilities do you have? How is the S/C build coming along and how are you feeling after your procedure man? I think I might have to buy my M5 cluster back from the guy I sold it to now that I know it can be properly and completely programmed to my 540iT.
I look forward to the updates.
Come on out. We have spare room. The ziggle has a weight limit. I'm not allowed
Brandon, no, but hope to meet him soon. He's not far from here. I think it was from Weatherford actually. I will have to look at my records.
Garages - house came with 3 parking spots (very tight but do-able). I later added another extra large 2-car with the lift. SC build is in progress. Currently doing the stuff shown at the end above - i.e. pulling valve covers and doing valley pan, etc. My high flow M60 manifold is delayed due to weather but should be here Monday. Then VF is sending a replacement AC line (the one in my kit won't fit and is wrong in several key ways). I'm feeling great up top, but my hip and back and leg are a bit sore from ice breaking a week ago and shoveling snow just this week. I'll live
Hopefully more updates later today. Going out to the shop now (heater has been running so it should be somewhat comfy).
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
Sweet!
Current
2005 E55 AMG
1998 Silverado K1500
1964 Impala
1964 Chevelle 496ci
Past
2000 Avus M5
1988 Suburban K1500
1987 Suburban K2500
2007 Suburban
1999 K2500 Suburban
2000 MGM
1999 K2500 Suburban
2001 Stratus 740i Msport
1990 750iL
1995 540i/6
1996 MGM
Nice thread. You're not too far from me.
2014//M5Comp (my DD) -- 2010 X5M (wife's) -- 90 Straman Z32TT (my pride & joy) -- 2006 F430 Spider -- 2015 McLaren 650S
Gone, but not forgotten: 01 E39 M5, 00 Dinan M5, 01 525i Sport, 03 DINAN 540i MSport, 91 Z32 TwinTurbo, 01 E53 3.0i, 06 Diann E53 4.8iS,
Very nice progress thread! Also nice euro dash too![]()
Former 2003 BMW 540i [Sterling Gray / Gray]
[Msport] [Near full Euro conversion] [M5 Interior] [Mods from A-Z]
Stuff For Sale :
See my ebay! [Click]
Awesome ride.
2001 BMW 540i 6-spd
Long posts ftw!
Man, love your garage! That's what I need. I have a car port, HOA does not allow work like that, so I do all that at the shop I work at, but have to finish up what I start before I leave, sucks! Nice work so far!
This morning I pulled the valve covers and intake manifold off. Currently cleaning all the mating surfaces and soon I hope to have the valley pan off and replaced with a new one, but for now it's family time. I'll get back to work later or maybe tomorrow.
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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
I'm in all fronts for this build. Looking good. Cleaning everything good is a big time killer. Good luck on the project.
98 540i 6, 525 whp, 120 mph 1/4, V3 Si S/C'er @16 psi, W/A I/C, Water/Meth, Supersprint Headers, HJS Cats, 3" Custom Exhaust, UUC Twin Disc, Wavetrac LSD, GC Coil Overs, Monoball TA, AEM FP, Aeromotive FPR, AEM Failsafe AFR/Boost, Style 65's w/275's, M5 Steering Box, Eibach Sways, M3 Shifter, Evans Coolant, 85 Deg Stat, PWM Fan, 10" Subs, B.A. speakers, Grom Aux/BT, Still Rolling as my DD!
You sure are, Philly. Extra special thanks and shout outs to geargrinder, JimLev, philly, and a fourth person who shall remain nameless.
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
Great thread. It's always nice to see owner who takes care of his car the way you do. Keep up the good work.
2010 BMW M6 SMG Coupe * Black Saphire Metallic * Full Leather Merino Black
2019 BMW X3 M40i * Alpine White * Mocha Leather
Former:
1997 BMW 532M (528i with 3.2 S52 engine from E36 M3 / 5 speed manual)
1998 BMW 540i 6 Speed
2003 BMW M5
I want your man cave.....
Awesome work so far.....do I spy an unbuffered temp gauge?
The AeroForce gauge reads coolant temp and other data from the OBD2 connector.
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
Nice work dude! Looks awesome. I'm jealous of your car lift, that makes things 100x easier than with jack stands.
1995 540i 6-speed - Thread
Ah yes. Coding issue now fixed. It's still buffered as before and stays vertical at ~185-230° F.
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
Seriously jelly of your pristine man cave. Sure, I have a lift and 12' ceilings with 30' depth, but I also have 3 teenagers with bikes, toys, projects(hey, at least Colin is happy turning a wrench on his beleaguered Wrangler) so access is seriously restricted and looks like a hoarder's paradise. Sigh. Maybe in 5 years when they are all gone.
Nice write-up and great project, although why anyone would want to tweak a long-roof when there's an M5 in the stable is beyond me. Must be an addiction.
2002 Schwartz II 530 5spd Sport Premium
2011 X5 35i
1966 Mustang f/b longterm project
1996 Malibu ski boat
9 1968-73 2002s, all gone......
1995 530i w/4.4 conversion (sold).
1985 535i w/mods, sorely missed.
BMWCCA member #110881
He who dies with the most toys, wins....
Another one that doesn't get the Tourings....
Nice build thread Redshift, just saw it.
Next on the list should be modding the ziggle so Aquila can ride it.
Your old valve covers have to be about the worst ones I've ever seen.
I'm heading over to my friend's house tomorrow to continue the cam chain guide job.
Gotta do some wrenching before the next snow storm tomorrow.
Last edited by JimLev; 02-28-2015 at 06:35 PM.
I like that gauge, looked for more info about it but the manufacturer doesn't show a BMW application...
Tenured Automotive Service Professional - Avid BMW Enthusiast
Bosch ABS2 Rebuild & Vapor Honing Service
I did some testing for them. It won't support all parameters but with the addition of a 2 bar MAP sensor, it will be more than sufficient for me. If you have questions let me know.
- - - Updated - - -
Jim, the valve covers are a huge mess. Flakes everywhere. Trying to keep things clean is a nightmare inside a horror show.
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
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