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Thread: Danny's Japan Rot 540i Touring Thread

  1. #926
    Join Date
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    E39 530i5 Sport
    Red zip tie drift stitch?

    Seriously, though, I wouldn’t bother to fix that bumper cover again. That’s a lot of damage that the plastic has taken over the years, and I’d bet it’s likely to split again. I’d source a new or used cover.
    Nate J. - Build Log
    (oOO\(|||)(|||)/OOo)

    RIP, Seabiscuit. Black Sapphire/Schwarz 03-11-2003 530iA Sport (CK39185). T-boned 03-01-2017 at 155,861mi.
    Take 2 "Otto" - Toledo Blue/Sandbeige 04-25-2002 530iA Sport (CH98032). Sold 11-10-2017 at 147,743mi.
    Take 3 "Manuel" - Toledo Blue/Grau
    10-29-2001 530i5 Sport (CE92358). 200k mi+ and going strong.

  2. #927
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    00 540it/97 M3/92 525it
    Quote Originally Posted by computiNATEor View Post
    Red zip tie drift stitch?

    Seriously, though, I wouldn’t bother to fix that bumper cover again. That’s a lot of damage that the plastic has taken over the years, and I’d bet it’s likely to split again. I’d source a new or used cover.
    Yeah I considered zip ties but the universe kinda made the decision for me. A week or two after the first major cracks, there were huge cracks all over the place. Eventually it started to kinda fall apart:



    There were cracks all over it, though oddly enough none of them were in the areas that I had previously repaired. I guess the bumper had just gotten brittle over the years, even though it was a real BMW bumper and not a rep. Eventually it fell apart so much that I had to just remove it. Thankfully I still had my prefacelift bumper laying around so I could still look presentable.





    I miss having an M5 bumper, so I'll probably get a rep and just deal with the less-than-stellar fitment. With my driving habits I would probably destroy a brand new $600 M5 bumper in no time— this one lasted less than a year! The crazy thing is that I've never hit anything obvious, nor have I crashed into anything. It's just been rocks and various bits of road debris that I either can't avoid or just don't notice. Ah well. Small price to pay in the grand scheme of things.
    2000 540i Japanrot Touring - Build Thread | 1997 M3 5-speed Coupe | 1992 525i Touring 5-speed - Build Thread
    Previously owned:
    2003 X5 4.6 - Build Thread | 2004 Range Rover HSE -Build Thread | 2000 M5 Anthracite/Caramel - Build Thread | 2003 540i6 M-Sport with 199k miles - Build Thread
    2000 540i/6 with 160k miles - Build Thread | 1995 750il with 188k miles - Build Thread | 2003 Mercedes S500 with 96k miles
    2001 540ia with 200k miles - Parts car/Garage couch

  3. #928
    Join Date
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    00 540it/97 M3/92 525it
    In my seemingly never-ending quest to make the rear of my wagon ride better, I adjusted the Koni shocks to full firm and then to full soft to see what would happen. Full firm was painful, as expected. Close to full soft feels a lot better though, and has made the ride a lot nicer overall, especially on the bumpy urban roads of Central Phoenix where I live.

    After adjusting the shocks I took a test drive with all of the rear panels removed to try and track down some more noises in the back, and I made an interesting discovery. I heard a scraping/dragging sound that only got louder with speed. It sounded like the brakes in the rear were dragging, and also I found that nearly all the brake squeal was coming from the back upon braking, not the front like I had previously thought. With an infrared thermometer, I did some testing and found that the rear brakes got consistently hotter by 40-50ºF, which was definitely abnormal given that the brake force is biased 70/30 front/rear.

    With that discovery, I went to my friend's house, jacked up the rear of the 540it, and tried to spin the rear wheels in neutral. They were oddly stubborn and didn't really want to spin much by hand. With the wheels off, I couldn't spin the rotors by hand at all. I removed the calipers and that didn't change anything, so it wasn't the brakes dragging. That meant it was the parking brake, so with the rotors removed, my friend and I adjusted both sides to be just right. There was a ton of parking brake shoe dust inside the rotors, so they've been dragging for quite some time. Crazy to think that I drag raced and took 11-hour road trips with the parking brake like that. That probably didn't help with gas mileage one bit, haha.

    Once the parking brakes were adjusted properly, I fully cleaned and lubed up all of the rear brakes and put everything back together. The first thing I noticed on the test drive was the complete lack of brake squeal. I don't think I've ever had zero brake squeal with this car so that alone was absolutely amazing. Even with me romping on the brakes in an abusive manner they didn't make a sound. The car felt a lot lighter and more willing to accelerate in general, which I was really stoked about. I can't believe I never thought about this before, but I never use the parking brake ever so it never even occurred to me that it wasn't working correctly. The car creeps forward in D now, whereas before it didn't really. The other benefit of fixing this is now I'll have a properly functioning parking brake for when the car gets a manual.

    Now that the car drove better than ever, I decided to treat it to a little cosmetic (and sorta functional?) mod:



    I don't really feel a difference with it installed but it sure gives it that racecar look, haha.

    I noticed I've been taking more pictures from the rear of the 540it, probably to hide my non-M front bumper shame. Probably.

    2000 540i Japanrot Touring - Build Thread | 1997 M3 5-speed Coupe | 1992 525i Touring 5-speed - Build Thread
    Previously owned:
    2003 X5 4.6 - Build Thread | 2004 Range Rover HSE -Build Thread | 2000 M5 Anthracite/Caramel - Build Thread | 2003 540i6 M-Sport with 199k miles - Build Thread
    2000 540i/6 with 160k miles - Build Thread | 1995 750il with 188k miles - Build Thread | 2003 Mercedes S500 with 96k miles
    2001 540ia with 200k miles - Parts car/Garage couch

  4. #929
    Join Date
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    Alexandria, VA
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    '01 540 Sport,'00 528iT
    Danny, every time you install new rotors, you have to adjust the parking brake as it auto adjusts, as the rotors wear.
    Set the controls for the heart of the sun

  5. #930
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    Virginia,USA
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    528i, 525iT, M5, x5 4.8
    Danny, what was the source of the strut bar?
    Current Garage
    2005 X5 4.8is Le Mans Met Blue
    2003 525iT TiSi
    2002 M5 TiSi
    1998 528i Champagne

    Former Garage Highlights
    2004 325iTs (2x)
    1973 Pantera
    1971 Dodge Dart Sport "Lite Package"
    1970 Dodge Challenger T/A 340 Six Pack Alpine White
    1970 Dodge Challenger T/A 340 Six Pack Go Man Go Green
    1969 Road Runner 383

  6. #931
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    Quote Originally Posted by BimmrMeUpSnotty View Post
    Danny, every time you install new rotors, you have to adjust the parking brake as it auto adjusts, as the rotors wear.
    Interesting, I wasn’t aware of that. I’ll keep that in mind for future brake jobs then.

    Quote Originally Posted by StephenVA View Post
    Danny, what was the source of the strut bar?
    It was in my 540i/6 parts car, so I just moved it over to the 540it. Not sure where it’s from originally, but I’d guess eBay.
    2000 540i Japanrot Touring - Build Thread | 1997 M3 5-speed Coupe | 1992 525i Touring 5-speed - Build Thread
    Previously owned:
    2003 X5 4.6 - Build Thread | 2004 Range Rover HSE -Build Thread | 2000 M5 Anthracite/Caramel - Build Thread | 2003 540i6 M-Sport with 199k miles - Build Thread
    2000 540i/6 with 160k miles - Build Thread | 1995 750il with 188k miles - Build Thread | 2003 Mercedes S500 with 96k miles
    2001 540ia with 200k miles - Parts car/Garage couch

  7. #932
    Join Date
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    Chicago, Il / Denver, Co
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    '01 DINAN7 '03 M5
    Ouch Denny, that looks painful
    Follow me on Instagram @nordmanmg

    Your current situation is not your final destination

  8. #933
    Join Date
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    1996 E320, 09 Accord V6
    Sucks about the bumper Danny. I’ve learned the hard way that old abs bumpers can’t really be repaired and last long term. And with the ridiculous price of used oem bumpers, I gave in and went aftermarket.

    Looking forward to the black interior swap and manual swap


    Sent from my iPhone using Tapatalk
    Chris
    -------------------------------------
    09 Accord V6 - reliable daily
    97 540i6 - weekend mistress

  9. #934
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    Quote Originally Posted by NordmanMg View Post
    Ouch Denny, that looks painful
    Yeah, it sucked but that's just life.

    Quote Originally Posted by cnsorial View Post
    Sucks about the bumper Danny. I’ve learned the hard way that old abs bumpers can’t really be repaired and last long term. And with the ridiculous price of used oem bumpers, I gave in and went aftermarket.

    Looking forward to the black interior swap and manual swap
    Yeah, now I know that. The funny thing is that the areas I repaired didn't break! The cracks were in new places, haha. I'll go aftermarket as well, fitment be damned.

    The black interior swap is going to have to wait a little while, because I'm preparing for the manual swap now. I recently started parting out my 540i/6 to get the transmission out and make some money to buy a new clutch/flywheel/short shifter/bushings/etc.

    2000 540i Japanrot Touring - Build Thread | 1997 M3 5-speed Coupe | 1992 525i Touring 5-speed - Build Thread
    Previously owned:
    2003 X5 4.6 - Build Thread | 2004 Range Rover HSE -Build Thread | 2000 M5 Anthracite/Caramel - Build Thread | 2003 540i6 M-Sport with 199k miles - Build Thread
    2000 540i/6 with 160k miles - Build Thread | 1995 750il with 188k miles - Build Thread | 2003 Mercedes S500 with 96k miles
    2001 540ia with 200k miles - Parts car/Garage couch

  10. #935
    Join Date
    Aug 2016
    Location
    Virginia,USA
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    780
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    528i, 525iT, M5, x5 4.8
    What gasket was NOT leaking on that 540?!
    Current Garage
    2005 X5 4.8is Le Mans Met Blue
    2003 525iT TiSi
    2002 M5 TiSi
    1998 528i Champagne

    Former Garage Highlights
    2004 325iTs (2x)
    1973 Pantera
    1971 Dodge Dart Sport "Lite Package"
    1970 Dodge Challenger T/A 340 Six Pack Alpine White
    1970 Dodge Challenger T/A 340 Six Pack Go Man Go Green
    1969 Road Runner 383

  11. #936
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    Quote Originally Posted by StephenVA View Post
    What gasket was NOT leaking on that 540?!
    Haha, that's what most M62tu's look like when they come to me. Nobody ever re-seals them aside from when the chain guide job is done, otherwise they just kinda seep for over a decade. It's not enough seepage to cause significant oil loss and the accessories cover it up pretty well, so most people don't pay any attention to it all.
    2000 540i Japanrot Touring - Build Thread | 1997 M3 5-speed Coupe | 1992 525i Touring 5-speed - Build Thread
    Previously owned:
    2003 X5 4.6 - Build Thread | 2004 Range Rover HSE -Build Thread | 2000 M5 Anthracite/Caramel - Build Thread | 2003 540i6 M-Sport with 199k miles - Build Thread
    2000 540i/6 with 160k miles - Build Thread | 1995 750il with 188k miles - Build Thread | 2003 Mercedes S500 with 96k miles
    2001 540ia with 200k miles - Parts car/Garage couch

  12. #937
    Join Date
    Dec 2010
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    Biddeford, Maine
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    2000 540I6 Sport
    Quote Originally Posted by dannyzabolotny View Post
    Yesterday I went on a fun little day trip with my girlfriend, we went from Phoenix to Sedona and then back to Phoenix through Payson. It was about 350 miles round trip, not bad at all. I managed to do all of that in less than a tank of gas— the M62tu loves highway driving. I did have some fun with it on the twisty roads to Payson though, the touring feels pretty good on them.

    The only downside was a silly little speeding ticket, for allegedly doing 64 in a 55. It's only a $62 ticket but still annoying. I need to invest in a radar detector already, as I have terrible luck with this kind of stuff— I'm completely oblivious and don't notice cop cars until they're like a few feet away. At least with something beeping at me I might pay more attention. The other annoying thing is that I get a ticket every single time I'm pulled over, like I don't ever get to talk my way out of it. Oh well. I'm not going to stop driving in a spirited manner any time soon so I should just have an annual budget for this kind of stuff.

    On the bright side, the touring looked and performed very well. No warnings or issues of any kind, and I'm almost at 203k miles.
    a little late to chime in on this, however.... I started driving in Phoenix. Received 14 speeding tickets in the 11 years I drove there. And beat 12 in traffic court.


    Danny, did it say “speed beyond safe and prudent” on the citation?

  13. #938
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    Quote Originally Posted by toybreaker View Post
    a little late to chime in on this, however.... I started driving in Phoenix. Received 14 speeding tickets in the 11 years I drove there. And beat 12 in traffic court.

    Danny, did it say “speed beyond safe and prudent” on the citation?
    Hm, I don't remember at this point. It wasn't in Phoenix though, it was in Payson. And it was a ticket for driving 64 in a 55 so it was pretty cheap. Wasn't really worth it to go to court especially since I didn't get any points from it.
    2000 540i Japanrot Touring - Build Thread | 1997 M3 5-speed Coupe | 1992 525i Touring 5-speed - Build Thread
    Previously owned:
    2003 X5 4.6 - Build Thread | 2004 Range Rover HSE -Build Thread | 2000 M5 Anthracite/Caramel - Build Thread | 2003 540i6 M-Sport with 199k miles - Build Thread
    2000 540i/6 with 160k miles - Build Thread | 1995 750il with 188k miles - Build Thread | 2003 Mercedes S500 with 96k miles
    2001 540ia with 200k miles - Parts car/Garage couch

  14. #939
    Join Date
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    Biddeford, Maine
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    2000 540I6 Sport
    The 2 i got “convicted” for were in rural Az.... local sheriffs and the hick judges are in cahoots,


    Its a conspiracy, lets make them city slickers pay for speeding in our area!

    ;-)


    Sent from my iPhone using Tapatalk

  15. #940
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    The speed above safe and prudent
    Takes time of day, weather, and traffic load into account in determining if it is unsafe to drive at that speed.....

    I used to work 4pm-3/6 am.... so traffic court was easy for me to get to. Always good weather and no traffic load so VERY easy for me to argue safe to drive 10-15 over posted. Time well spent to see the look on the police officer/DPS officer’s face when it was dismissed.... those role models speed everywhere.........


    Sent from my iPhone using Tapatalk

  16. #941
    Join Date
    Jun 2014
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    Acton, IN
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    330i ZHP, 03 525iT Sport
    Quote Originally Posted by toybreaker View Post
    The speed above safe and prudent
    Takes time of day, weather, and traffic load into account in determining if it is unsafe to drive at that speed.....

    I used to work 4pm-3/6 am.... so traffic court was easy for me to get to. Always good weather and no traffic load so VERY easy for me to argue safe to drive 10-15 over posted. Time well spent to see the look on the police officer/DPS officer’s face when it was dismissed.... those role models speed everywhere.........


    Sent from my iPhone using Tapatalk
    So you would just simply argue that it was safe and prudent based on conditions to drive 10-15 over?

  17. #942
    Join Date
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    E39 530i5 Sport
    The police in my area are perhaps the most aggressive and dangerous drivers...
    Nate J. - Build Log
    (oOO\(|||)(|||)/OOo)

    RIP, Seabiscuit. Black Sapphire/Schwarz 03-11-2003 530iA Sport (CK39185). T-boned 03-01-2017 at 155,861mi.
    Take 2 "Otto" - Toledo Blue/Sandbeige 04-25-2002 530iA Sport (CH98032). Sold 11-10-2017 at 147,743mi.
    Take 3 "Manuel" - Toledo Blue/Grau
    10-29-2001 530i5 Sport (CE92358). 200k mi+ and going strong.

  18. #943
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    Quote Originally Posted by simmsled View Post
    So you would just simply argue that it was safe and prudent based on conditions to drive 10-15 over?
    It is how the traffic safety regulations were written. I was able to convince the court that due to “relative” time of day, weather and traffic conditions it was safe to drive at that speed.
    That was 1989-2001, not sure of how the regulations are written now.
    with age comes wisdom, now i try not to get pulled over.

  19. #944
    Join Date
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    No super exciting updates, just wanted to log what's happening. I'm almost at 208k miles, which means it'll be time for an oil change pretty soon. Thinking of using Liqui-Moly 5W40 this time around— my friend has it in his 200k mile 2002 540it and seems to be happy with it so I'll give it a shot.

    Other things to report— my gas tank leak has gotten worse, now there's a puddle every time I fill the tank fully. My solution is to not fill the tank fully, which has worked for now while I'm mostly driving around town. I'll look into it some more in the coming days, hopefully it's an easy fix. I've already replaced the gasket on the fuel sender, so I guess either that wasn't the source of the leak or it's still leaking.

    Transmission has actually been behaving quite well recently— it likes the 100ºF heat! So odd. Again, I'm choosing to ignore all of its faults since a manual swap is in the very near future.

    Speaking of the manual swap, the engine + transmission have been pulled out of the 540i/6 parts car (thanks to Graham for the help!). Eventually I'll split the two and start ordering new parts for the manual swap. Though first I need to sell some more stuff off the parts car, including the engine. My wishlist is a new M5 clutch, flywheel (if needed), DSSR, E60 545i short shifter, ZHP shift knob, new leather shift boot, new shifter bushings, clutch pedal bushings, and any other bushings that might need to be replaced while everything is out.

    The black interior swap will be happening at some point too... might happen sooner than the manual swap since I already have all the parts and it won't cost me anything to swap, aside from maybe a few new clips here and there.

    As for the bumper situation, I've decided that I'm going to wait until I can afford a new OEM bumper instead of settling for a replica. None of the replicas fit quite right and while some can live with that, I cannot. I need perfect fitment or else I'll go crazy.
    2000 540i Japanrot Touring - Build Thread | 1997 M3 5-speed Coupe | 1992 525i Touring 5-speed - Build Thread
    Previously owned:
    2003 X5 4.6 - Build Thread | 2004 Range Rover HSE -Build Thread | 2000 M5 Anthracite/Caramel - Build Thread | 2003 540i6 M-Sport with 199k miles - Build Thread
    2000 540i/6 with 160k miles - Build Thread | 1995 750il with 188k miles - Build Thread | 2003 Mercedes S500 with 96k miles
    2001 540ia with 200k miles - Parts car/Garage couch

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