Hi all. I purchased a 2003 540i M Sport Touring sight unseen in Feb 2017 from a dealership in California and had it transported up to Seattle. My wife and I do a fair amount of fostering for a local rescue organization, so we needed a car that could transport a bunch of animals at a time. E39s were new back when I was in high school and I've always wanted one. I halfheartedly peruse Craigslist on a regular basis and when this one popped up, it seemed like a good idea. There were no maintenance records, so I'm doing everything that potentially needs to be done. This thread will serve as a maintenance record for me (and because Plattus told me to make this thread).
Here's whats been done so far:
- Radiator, expansion tank, water pump, thermostat, clutch fan, all main cooling hoses replaced
- Rebuilt VANOS units
- Timing chain guides replaced < I retimed the car three times because I kept on getting P0011/P0021 codes from using crappy eBay timing blocks and VANOS jigs. Was perfect the first time using the GAS tools.
- Oil separator replaced
- Crank pulley seal replaced
- Rebuilt injectors with new o-rings, filters and washers
- CCV replaced and torx bolts replaced with normal bolts
- Intake manifold gaskets replaced
- Rear coolant accumulator gaskets replaced
- Spark plugs and coil boots replaced
- Valve covers powdercoated by Plattus
- E60 hub and bearing conversion < took 2 weeks of heat, PB blaster and hitting with a 12lb sledge to knock the axle out
- New rotors and pads all around < one of the Meyle Platinum rotors wouldn't fit onto the hub. I had to file the internal lip down...
- Rear SLS airbag replacement < I used Aerosus bags
- Transmission filter and pan gasket replaced < used Valvoline MaxLife ATF and it works fine
- Replaced staggered 20" BBS LM reps (ESM004 I believe) with square Apex ARC8 18x9.5 ET22 with 265/35 rubber all around < I needed 7mm spacers in the front to clear the KW coils the car came with
- Installed Euro tails (from eBay via Lativa) to replace the blacked out tails
- Replaced air filter
- Oil changed
- Motor and tranny mounts replaced
- Replaced other random gaskets and o-rings in the process of doing the above
Still to do:
- alignment
- Scuba tank delete < I've driven my friend's 540 sedan with the scuba delete and whatever drone there is doesn't bother me
- fabricate some SLS links to RAISE the rear 1/4in to match fender gaps < I know I can do this in INPA, but I've been having a hard time getting it to work on my laptop
- replace fuel filter
- replace diff fluid
- replace cabin air filters eventually
- replace windshield rubber trim and and door weather stripping < dry rot from California sun
- reseal door vapor barriers
- figure out why the windshield sprayer doesn't work
- replace a couple soft brake lines and then replace brake fluid
- replace rear subframe bushings eventually
- DUDMD tune?
- E39 M5 LSD swap? < no manual swap as my wife needs to be able to drive the car too
- touring spoiler from Plattus?
Only picture I have with its older/more wild brother:
Last edited by nauqneyugn; 06-12-2017 at 12:04 AM.
1995 525i 5-speed - Thread
We have traveled similar paths. I too have an '03 540iT and an Alpinweiss E30 M3.
To address some of your questions:
I used INPA to lower rear to match the front height (Dinan)
DUDMD tune - worth the money and time in my instance
Addressing the soft brake pedal feel was a priority for me - Cool Carbons, stainless lines, and brass guide pins with successful result
Scuba delete - I replaced with Magnaflow polished stainless. No drone and nice WOT sound.
Windshield sprayer - easy access to pumps (mine has three) inside rf fender liner. Does your rear sprayer work?
I used INPA to lower my touring's rear as well, and I did a muffler delete which sounds great. All I have is the resonator and then it's a straight pipe after that. I'd almost say it's too quiet haha
1995 525i 5-speed - Thread
If your is a true M Sport, does that mean it was produced for only 03, with a single exhaust outlet on the driver's side? My friend just bought an 03 M sport sedan. I didn't realize there was a different between the sport and the M sport. I believe the M sport has all the M5 upgrades except the engine.
Minor updates:
- Installed M5 rear sway bar
- Scuba delete > butt dyno says it feels slower, but I'm probably wrong
- Technical graphite trim installed
- New windshield wipers!
Quick question on the rear M5 bar. I have installed them on sedans with no issues. It was my understanding that on Air suspension wagons it will not fit unless the front subframe bushing mounts are modified or replaced with the sedan parts.
True? or is just a bolt on like the sedans? Only new brackets/bushings and end links required....
Current Garage Highlights
2003 525iT TiSilver
2002 M5 TiSilver
1998 528i KASCHMIRBEIGE METALLIC (301) (Goldie)
Former Garage Highlights
2005 X5 4.8is
2004 325iTs (2x)
1973 Pantera L
1971 Dodge Dart Swinger "Lite Package"
1970 Dodge Challenger T/A 340 Six Pack Alpine White
1970 Dodge Challenger T/A 340 Six Pack GoManGo Green
1969 Road Runner 383
1968 Barracuda Formula S 340 Sea Foam Green
I believe you're referring to the M5 rear subframe traction bars, which need to have the sedan bushings on the front two spots on the rear subframe in order to fit. The rear sway bar is completely bolt on and you just need new bushings with the larger diameter. I reused my brackets (maybe they'll break eventually) and endlinks. Hope this helps.
Thanks. I plan on adding all the above.
Current Garage Highlights
2003 525iT TiSilver
2002 M5 TiSilver
1998 528i KASCHMIRBEIGE METALLIC (301) (Goldie)
Former Garage Highlights
2005 X5 4.8is
2004 325iTs (2x)
1973 Pantera L
1971 Dodge Dart Swinger "Lite Package"
1970 Dodge Challenger T/A 340 Six Pack Alpine White
1970 Dodge Challenger T/A 340 Six Pack GoManGo Green
1969 Road Runner 383
1968 Barracuda Formula S 340 Sea Foam Green
Actually Hankook Tires in Lynnwood. I get all my tires, balancing and alignment done there. They're good people!
DUDMD tune happening in a couple weeks when I have some time off work.
Swapped black for chrome kidneys and washed it!
IMG_1483.jpg
New cowl and water diverter things on the sides of the cowl! Doesn't smell like ATF inside anymore!
DUDMD tune - with my normal driving, I didn't notice an increase in power, but the throttle response is noticibly better. I would like it to be even more sensitive, but it doesn't bother me as much anymore.
Rear subframe bushings - borrowed Jed's tool and it was very straightforward. The 24mm ratcheting wrench that was usually included was broken, so I used a normal 24mm wrench. It would have been way easier with some ratcheting action. I noticed my car rocks slightly on braking, so hopefully this helps. Otherwise, I'll have stiffen up the Konis a bit.
Do the '03 540i tourings come with a Limited Slip or Open Dif? I've heard it both ways.
'98 M3 5spd - '03 540it 6spd M-Sport
They all came with open diffs, the only thing that was different was that they got the 3.15 rear diff ratio. It gets the heavy 540it going pretty well and you can do some decent one-leg burnouts for sure (have personally done many, can confirm). If you want an LSD you have to either swap the diff internals with something like a Quaife/Wavetrac or get an M5 diff and figure out the driveshaft/axle situation since it's not 100% plug-and-play.
1995 525i 5-speed - Thread
Yeah I'm trying to figure out which is the more cost effective option for getting an LSD, M5 or Quaife/Wavetrac. I have no idea how much having the driveshaft modified is if I wanted to go the M5 route.
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