Page 1 of 2 12 LastLast
Results 1 to 25 of 34

Thread: GN92445 Maintenance Thread

  1. #1
    Join Date
    Oct 2012
    Location
    Seattle
    Posts
    67
    My Cars
    88 M3, 03 M Sport Wagon

    GN92445 Maintenance Thread

    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.

  2. #2
    Join Date
    Jul 2012
    Location
    mitten
    Posts
    3,760
    My Cars
    525it,02 525it,73 2002
    I want the M3


  3. #3
    Join Date
    Jan 2015
    Location
    Tempe, AZ
    Posts
    7,657
    My Cars
    1995 525i/5
    Quote Originally Posted by jp5Touring View Post
    I want the M3
    I'd rather have the touring tbh. The E30 M3 doesn't do much for me. The only reason I'd want one is to sell it for way too much money to an enthusiast :P
    1995 525i 5-speed - Thread

  4. #4
    Join Date
    Sep 2006
    Location
    Gainesville, GA, USA
    Posts
    449
    My Cars
    M6 Turbo,E30 M3,540iT
    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?

  5. #5
    Join Date
    Jan 2015
    Location
    Tempe, AZ
    Posts
    7,657
    My Cars
    1995 525i/5
    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

  6. #6
    Join Date
    Feb 2014
    Location
    Seattle wa usa
    Posts
    1,641
    My Cars
    2003 546it m-sport
    Glad you started a thread. Don't let anyone tell you that your e30 isn't amazing. Just typically razzing from the touring group. You still get respect.

    More pics man!

  7. #7
    Join Date
    Jun 2012
    Location
    Mundelein, IL
    Posts
    837
    My Cars
    840Ci/6 528iT Europa TCS
    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.

  8. #8
    Join Date
    Oct 2012
    Location
    Seattle
    Posts
    67
    My Cars
    88 M3, 03 M Sport Wagon
    Back from an alignment this morning:





  9. #9
    Join Date
    Oct 2012
    Location
    Seattle
    Posts
    67
    My Cars
    88 M3, 03 M Sport Wagon
    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!

  10. #10
    Join Date
    Dec 2008
    Location
    Long Island
    Posts
    505
    My Cars
    528iT
    Quote Originally Posted by nauqneyugn View Post
    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!

    It's Prolly just me but I love new wipers and a freshly waxed windshield. Water just beads right off...

  11. #11
    Join Date
    Feb 2014
    Location
    Seattle wa usa
    Posts
    1,641
    My Cars
    2003 546it m-sport
    Look'n good.

  12. #12
    Join Date
    Aug 2016
    Location
    Virginia,USA
    Posts
    3,144
    My Cars
    528i, 525iT, M5
    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

  13. #13
    Join Date
    Oct 2012
    Location
    Seattle
    Posts
    67
    My Cars
    88 M3, 03 M Sport Wagon
    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.

  14. #14
    Join Date
    Aug 2016
    Location
    Virginia,USA
    Posts
    3,144
    My Cars
    528i, 525iT, M5
    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

  15. #15
    Join Date
    Feb 2014
    Location
    Seattle wa usa
    Posts
    1,641
    My Cars
    2003 546it m-sport
    Quote Originally Posted by nauqneyugn View Post
    Back from an alignment this morning:




    Someone went to les schwab. Look'n good man. Love the progress.

  16. #16
    Join Date
    Oct 2012
    Location
    Seattle
    Posts
    67
    My Cars
    88 M3, 03 M Sport Wagon
    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.

  17. #17
    Join Date
    Feb 2014
    Location
    Seattle wa usa
    Posts
    1,641
    My Cars
    2003 546it m-sport
    They use the same alignment machine it seems.

  18. #18
    Join Date
    Oct 2012
    Location
    Seattle
    Posts
    67
    My Cars
    88 M3, 03 M Sport Wagon
    Swapped black for chrome kidneys and washed it!

    IMG_1483.jpg
    Attached Images Attached Images

  19. #19
    Join Date
    Oct 2012
    Location
    Seattle
    Posts
    67
    My Cars
    88 M3, 03 M Sport Wagon
    New cowl and water diverter things on the sides of the cowl! Doesn't smell like ATF inside anymore!
    Attached Images Attached Images

  20. #20
    Join Date
    Oct 2012
    Location
    Seattle
    Posts
    67
    My Cars
    88 M3, 03 M Sport Wagon
    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.
    Attached Images Attached Images

  21. #21
    Join Date
    Jul 2012
    Location
    mitten
    Posts
    3,760
    My Cars
    525it,02 525it,73 2002
    Nice work,still want the M3.


  22. #22
    Join Date
    Feb 2007
    Location
    San Diego, CA
    Posts
    1,743
    My Cars
    98 M3, 03 540it M-Sport
    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

  23. #23
    Join Date
    Nov 2016
    Location
    orchard park, NY
    Posts
    59
    My Cars
    04' 330xi
    Quote Originally Posted by QtheGenius View Post
    Do the '03 540i tourings come with a Limited Slip or Open Dif? I've heard it both ways.
    open

  24. #24
    Join Date
    Jan 2015
    Location
    Tempe, AZ
    Posts
    7,657
    My Cars
    1995 525i/5
    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

  25. #25
    Join Date
    Oct 2012
    Location
    Seattle
    Posts
    67
    My Cars
    88 M3, 03 M Sport Wagon
    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.

Page 1 of 2 12 LastLast

Similar Threads

  1. My 2000 528it repair/maintenance thread
    By johngilesyoder in forum E39 Touring / Wagon
    Replies: 10
    Last Post: 12-01-2013, 10:21 PM
  2. My 95 740i build/maintenance thread
    By aythatblackguy in forum 1995 - 2001 (E38)
    Replies: 4
    Last Post: 10-16-2013, 08:37 AM
  3. My 1998 M3 Sedan maintenance thread
    By lonehousewife in forum 1992 - 1999 M3 (E36)
    Replies: 1
    Last Post: 06-27-2013, 06:19 PM
  4. HokiE36's BUDGET 99 M3 build & maintenance thread
    By hokie36 in forum 1992 - 1999 M3 (E36)
    Replies: 3
    Last Post: 06-07-2011, 04:12 PM
  5. ALOT of maintenance threads......
    By adamlp in forum 1992 - 1999 M3 (E36)
    Replies: 22
    Last Post: 10-29-2010, 09:38 AM

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •