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Thread: Project 560i: my E39 LSx build

  1. #26
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    A long overdue update:

    I finally finished the overhaul on the 4L80E.
    Had the converter rebuilt and stall raised.
    Finished the cooling system plumbing (still need the efans).
    Finished the fuel system plumbing (still need to upgrade the pump).
    Finished 90% of the wiring (still need to wire the EZ-TCU).
    Bought a 2017 Mustang GT catback ($50, yay Craigslist) to mate up with the axle forward section of the 2010 Camaro SS catback ($25, yay Craigslist).

    Starting the exhaust down pipes now so I can fire up the engine in-car before winter puts the brakes on the project until things warm back up.

    DA360137-9D0C-46EB-91D8-6E2082D90AF5.jpg

    84AE212C-8CA9-41FA-B71E-0464151A3867.jpg

    023E0539-2122-4B4C-9609-5DB7C9F858B5.jpg

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    Pic overflow to post #27

    S.F.
    Last edited by StolenFox; 07-02-2017 at 09:40 AM.

  2. #27
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    A little update

    Overflow pic from post #27.

    C269D661-6880-43B5-AC79-4AAA54EB4CB4.jpg

    Last edited by StolenFox; 07-02-2017 at 09:42 AM.

  3. #28
    Join Date
    Oct 2008
    Location
    West coast
    Posts
    1,316
    My Cars
    '00 540 6.0/4L80e/S480
    Quote Originally Posted by StolenFox View Post
    Great progress! How bad is the itch to drive it?

  4. #29
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”
    Quote Originally Posted by unnatrl View Post
    Great progress! How bad is the itch to drive it?
    unbearable! To bad it's going to be quite a while, winter is going to shut me down soon....

  5. #30
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    Today's update: Exhaust phase 1

    Today I built the converter down pipes using the 2010 Camaro SS parts, mandrel bends and new stainless flanges.

    644EC59F-41E2-45CD-9CA9-272DE2FB0F72.jpg

    188FEC9C-F186-4D09-B755-36202FC3F583.jpg

    40AE5A37-B142-45DE-9AF8-5203CEC2C077.jpg

    S.F.
    Last edited by StolenFox; 07-02-2017 at 09:47 AM.

  6. #31
    Join Date
    Apr 2012
    Location
    Stuttgart, Germany
    Posts
    577
    My Cars
    1997 M3 / 5.3
    Wonderful feeling hear it come alive, I'm sure. Slick work on the exhaust too!

  7. #32
    Join Date
    Oct 2008
    Location
    West coast
    Posts
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    '00 540 6.0/4L80e/S480
    The exhaust looks awesome!

  8. #33
    Join Date
    Apr 2011
    Location
    Somewhere, USA
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    My Cars
    2000 “560i”
    Quote Originally Posted by Tim Mc View Post
    Slick work on the exhaust too!
    Quote Originally Posted by unnatrl View Post
    The exhaust looks awesome!
    Thank you gentlemen, I appreciate it!

    Between the transmission install and working on the exhaust (without the benefit of a lift) I'm feeling all 40 years today.....

    S.F.

  9. #34
    Join Date
    Jun 2011
    Location
    Buffalo, NY
    Posts
    1,703
    My Cars
    2001 BMW 540i/6
    Sweeeeeeeeeet! I like the intake, flip it upside down and cut a hole in the hood.

    2001 BMW 560i 6.0 LSx/T56 SOLD


    2000 Corvette Hardtop FRC

  10. #35
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
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    2000 “560i”
    Quote Originally Posted by nsogiba View Post
    Sweeeeeeeeeet! I like the intake, flip it upside down and cut a hole in the hood.
    Yeah, intake was a hack using C5 stuff from my engine run stand. Not pretty but it let me run the engine! After I cut the hole in the hood I figured I'd paint it orange and weld the doors shut!

    S.F.

  11. #36
    Join Date
    Apr 2011
    Location
    Somewhere, USA
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    My Cars
    2000 “560i”

    A painfully little update...

    Slowly reworking the harness to add all the emissions hardware back in and switch from DBW to DBC. Also switched from the truck PCM to 04 GTO

    FF7F81E2-E04C-45AA-8E4C-C87434B2C9E3.jpg

    Amazingly the 04 GTO evap canister vent solenoid is a perfect fit for the E39 Charcoal canister. Just had to make a bracket that mimics the E39 leakage detection pump mounting setup.

    428F2178-9BE9-4492-9DD9-3A3858C6CB41.jpg

    Also started fabricating the buikhead fitting I need to mount the GM fuel tank pressure sensor in the E39 fuel level sender / pump mount flange.

    DA41F687-7301-41E8-8A95-6ACF438E3B79.jpg

    Mounted the B&M transmission cooler where the E39 Aux cooling fan used to reside.

    AF6ACE99-264D-4893-B282-9B993ABB3C9B.jpg

    83080F41-B603-4330-870A-0B017CB51883.jpg

    And chopped up the ghetto eBay Silverado cold air kit to get it in the car. It's crap, no quality at all so it is definitely temporary.

    Pic overflow to Post #38

    S.F.
    Last edited by StolenFox; 07-02-2017 at 09:57 AM.

  12. #37
    Join Date
    Oct 2008
    Location
    West coast
    Posts
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    '00 540 6.0/4L80e/S480
    Sooo, test drive this weekend?

  13. #38
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
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    My Cars
    2000 “560i”
    Overflow Pic from post #36

    9D7C6B02-0004-424C-8D20-A8188E04FA27.jpg

    Quote Originally Posted by unnatrl View Post
    Sooo, test drive this weekend?
    I wish, here's the list:

    install evap vent
    install tank pressure sensor
    figure out how the fuel level signal to the PCM (dual Sender on passenger side maybe) and install it.
    install electric fan
    switch 4L80e cooler fittings, run AN hose from trans to cooler
    install Lokar 4L80E dipstick
    fill trans with ATF
    install EZ-TCU
    pull 6-cyl diff and axles
    reinforce diff mount
    install 540i diff and axles
    measure driveline and have modified
    install drivveline
    cutout and raise the spare tire well.
    finish the exhaust
    buy and install Lokar shifter

    do the 100 things I probably forgot about.

    Pray everything jives.
    Maiden voyage.

    S.F.
    Last edited by StolenFox; 07-02-2017 at 09:58 AM.

  14. #39
    Join Date
    Oct 2008
    Location
    West coast
    Posts
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    '00 540 6.0/4L80e/S480
    I'm having flashbacks... that stuff took me months to complete. I thought you were a little closer for some reason. Either way, stay at it!

  15. #40
    Join Date
    Apr 2011
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    Somewhere, USA
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    My Cars
    2000 “560i”
    Big day for the project: successfully fired the engine with the harness reworked to drive by cable, new, 04 GTO PCM, emissions hardware added and the EZ-TCU mocked up. Doesn't sound like much but with all the wiring changes it's a big deal. Oh and the transmission seemed to be ok, no leaks or weird noises when I lit it up. Gotta a rear O2 error so I need to check my wiring but it was a good day!

    S.F.
    Last edited by StolenFox; 10-29-2016 at 09:41 PM.

  16. #41
    Join Date
    Oct 2008
    Location
    West coast
    Posts
    1,316
    My Cars
    '00 540 6.0/4L80e/S480
    Congrats! The thats a huge victory.

  17. #42
    Join Date
    Jun 2015
    Location
    Anchorage, Alaska
    Posts
    23
    My Cars
    1997 BMW 540iA
    Great job! It takes quite a bit of thought and ingenuity to work through all of the issues/roadblocks. Subscribed!

  18. #43
    Join Date
    Apr 2011
    Location
    Somewhere, USA
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    My Cars
    2000 “560i”
    Well, I still stink at Tig welding aluminum! Reinforcing the diff mount was a real bear but I got it done. Was unable to reach the left side of the front of the mount, even with the short tungsten cap I couldn't get the torch in there. So it's going to have to stay as is.

    A33AE062-A6A4-42BC-910E-538DB2787E3E.jpg

    4E8B7639-5642-44F5-B41E-62782CB2A4E9.jpg

    FA2699F2-682C-4CCB-8103-67BD4D8A3687.jpg

    S.F.
    Last edited by StolenFox; 07-02-2017 at 10:02 AM.

  19. #44
    Join Date
    Jun 2011
    Location
    Buffalo, NY
    Posts
    1,703
    My Cars
    2001 BMW 540i/6
    Any reason you didn't just pull the subframe out? It's easy, especially with all that crap out of the way.

    2001 BMW 560i 6.0 LSx/T56 SOLD


    2000 Corvette Hardtop FRC

  20. #45
    Join Date
    Apr 2011
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    Somewhere, USA
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    2000 “560i”
    Quote Originally Posted by nsogiba View Post
    Any reason you didn't just pull the subframe out? It's easy, especially with all that crap out of the way.
    Well, that would have been easier except she's a long way off the ground:

    644EC59F-41E2-45CD-9CA9-272DE2FB0F72.jpg

    And I don't have stands tall enough to reach the rocker pads. Most likely this is all temporary since M5 diff's and axles are priced like gold I'll probably buy another subframe and mod it for a Ford 8.8 from an IRS Explorer. Custom axles will be expensive but at least the sky's the limit when it comes to gear and Posi options.

    SF.
    Last edited by StolenFox; 07-02-2017 at 10:03 AM.

  21. #46
    Join Date
    Apr 2011
    Location
    Somewhere, USA
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    My Cars
    2000 “560i”

    Another long overdue update.

    After reinforcing the diff mount I've installed the axles and the differential. Also, borrowed a tech 2 scanner and performed the crank angle variation learn to clear the check engine light. Pulled the shifter assembly and ordered some stuff from Shiftworks to hopefully build a cable operated shifter using a factory BMW unit from a early E39. I also bought a universal aluminum fan shroud and modified a Taurus 2-speed efan to fit:

    9B0B0DB4-DB7A-417E-8E0D-66D8CD24AFE1.jpg

    02C1326A-A574-4D43-A438-1202AB4BAA9F.jpg

    C1F1B1F3-7BA4-4B36-BDCB-C7A3FF4060E8.jpg

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    6566A221-F25A-4D9E-A046-60EC3239DCD1.jpg

    Overflow pic post #47

    Still have to paint, install & wire but this is a good start.

    S.F.
    Last edited by StolenFox; 07-02-2017 at 10:10 AM.

  22. #47
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
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    My Cars
    2000 “560i”

    Efan is in and 100% operational

    Overflow pic from post #26

    78564DBA-1E8C-44D6-BA4B-65F45AEE2C07.jpg


    Taurus two speed fan with a Volvo Fan relay controlled by the LS PCM ground trigger.

    1D567081-DCF2-4C6B-B822-8D9EA887202C.jpg
    S.F.
    Last edited by StolenFox; 07-02-2017 at 10:13 AM.

  23. #48
    Join Date
    Apr 2011
    Location
    Somewhere, USA
    Posts
    247
    My Cars
    2000 “560i”

    Today's project: Fuel Pump and sender mods

    So since it's 20 degrees in my garage I decided to bring a spare pump module to the kitchen table for modification. For my emissions legal swap I had to incorporate the fuel tank pressure and level senders from the 04 GTO to my E39 pump module:

    3B8B45AA-B9D1-4E9D-A3E5-100330CF17CE.jpg

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    5442B89C-80F6-4086-A750-AE2628C01FBF.jpg

    See post #50 for overflow pics.

    To do so, I built a bulkhead fitting for the pressure sensor and made mounting bracketry for the GTO fuel sender. To get the GM sender signal out of the tank I added two additional BMW pins to the BMW module in the unused slots in the middle of the Electrical connector. Just drilled the unused spots, pressed in the pins and connected to the GTO sender. I'll add the corresponding female pins to the car's pump wiring connector to complete the circuit to the GM pcm.

    S.F.

    - - - Updated - - -

    Oh yeah, I also installed the Fuel Lab 340lph pump to the basket...

    S.F.
    Last edited by StolenFox; 07-02-2017 at 10:27 AM.

  24. #49
    Join Date
    Apr 2011
    Location
    Somewhere, USA
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    My Cars
    2000 “560i”

    Finally a warm day so:

    I welded the V-bands to the cat pipes and intermediate H-pipe. Used some bends to reduce the pipe centerline so I could get past the fuel tank:

    97731258-5F34-4C50-9D5E-04AE7181AD62.jpg

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    Installed the intermediate pipe hangers and modified the factory plate to help support them:

    815C1A3D-6D98-4CE3-88D2-AFA387714E8A.jpg

    And then mounted it back up:

    See post #50 for overflow pics.

    Mocked up the 2016 Mustang GT catback to see how it would work, fits amazingly well:

    See post #50 for overflow pics.

    Lastly, check out the awesome factory GM booger weld on the intermediate pipe:

    See post #50 for overflow pics.

    S.F.
    Last edited by StolenFox; 07-02-2017 at 10:34 AM.

  25. #50
    Join Date
    Apr 2011
    Location
    Somewhere, USA
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    My Cars
    2000 “560i”

    So this happened:

    Overflow pics from posts #48 and #49:

    27D46D97-1ABB-4186-84E1-FE23B72010BF.jpg

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    105819A4-DAEB-405A-AF32-A8CB0AE26A07.jpg





    Sorry, don't know how to edit videos and they suck. Too excited to care!

    S.F.
    Last edited by StolenFox; 07-02-2017 at 10:39 AM.

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