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Thread: MotorMouth93's 2003 540i/6 Quasi-Restoration Build Thread

  1. #1
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    MotorMouth93's 2003 540i/6 Quasi-Restoration Build Thread

    Edit: I cleaned this thread out but am slowly putting it back.

    Hey guys! I'm brand new to the forum and new to BMWs but I've been around cars for a while now. Before buying the 540 I had a 1999 Integra and a 1994 NSX, but the Integra was totaled when an SUV rear-ended me at a stoplight and pushed me into the car in front. Since the Integra died and I don't want to daily the NSX, I started looking for a suitable replacement. I was looking for something quiet, comfortable, enough room to be practical, manual, fun to drive, and around the 10k price point. From my research I'm expecting to spend a good deal more maintaining this car than I have with my Hondas, but I'm not too worried since I do all my own work and 540 parts are pretty cheap.


    More info about my previous cars and the work I've done on them can be found in these build threads: 1994 NSX, 1999 Integra


    Anyways, about the car, 2003 540i MSport, 6-speed manual, ~93,000 miles, sapphire metallic black, black interior. The exterior of the car is in great shape, I know a few panels have been repainted but they match perfectly and the only real exterior flaws are minor door dings that will get taken care of during my PDR appointment on Monday. The interior is in good shape as well except for the pillars which are peeling, no rips or tears anywhere on the seats or other upholstery though.


    The previous owner also had a massive stack of service records, within the past couple years it's had a cooling system work, Dr. Vanos VANOS solenoids installed, valve cover gaskets, etc. done. The only real mechanical issue at this point is a slipping clutch, but I was able to get a decent discount because of it so I'm happy.


    First few photos, I'll be posting a lot more as I start tearing into things.








    The car is not without it's faults though, I have a fairly long punch list of minor stuff to take care of along with minor modifications.


    • Replace clutch (ordered)
    • Replace shifter bushings (ordered)
    • E60 short shifter (ordered)
    • ZHP shift knob (ordered)
    • Replace transmission fluid (ordered)
    • Replace RMS (ordered)
    • Replace input shaft seal (ordered)
    • Replace output shaft seal (ordered)
    • Fix headlight adjusters (ordered)
    • Morimoto FX-R HID projector retrofit (already have)
    • Brand new Umnitza lenses since 2003 headlights have to be cut open (ordered)
    • Orion V2 angel eyes (ordered)
    • Touch up minor scrapes on the bottom of the bumper lip
    • Very slight PS leak at the hose
    • Very slight valve cover seep
    • Change oil/filter (picking up supplies at dealership)
    • Brake fluid flush/bleed
    • Replace passenger side rear window regulator (ordered)
    • Fix driver seat lumbar support
    • Disconnect seatbelt height adjuster cables, my girlfriend is tiny so the belt cuts into her neck.
    • Get new keys with functional keyless entry
    • Can't open the trunk with the key, need to inspect the linkage
    • Replace bluish interior LEDs with warmer LEDs
    • Install front and rear dash cameras, likely going to be Blackvue DR470.
    • Replace chipped badges (supplied by previous owner)
    • Replace front and rear windshield moldings (supplied by previous owner)
    • Paint correction (have equipment already)
    • CQuartz ceramic coating (already have)
    • MAYBE: PPF on front bumper, side skirts, fenders, hood. (already have a roll of film)
    • MAYBE: Rebuild + powdercoat brake calipers, I have blasting and powder coating equipment so I might get around to this at some point. Once you've had powdercoated calipers you can't go back, they are so much easier to keep looking nice. Brake dust just wipes off.
    • Electric exhaust cutout before the muffler, I like having a quiet car but I also want V8 noises. I have an aftermarket exhaust on the NSX and I love it, but sometimes it's annoying so I don't want to go that route here.
    Last edited by MotorMouth93; 08-01-2022 at 11:43 PM.

  2. #2
    JimLev's Avatar
    JimLev is offline Artifically Aspirated Moderator
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    Welcome to the E39 forum.
    Don't forget to get a new pressure plate and throw out bearing. If you plan on using your old one it will need to be reset as it is a self adjusting pressure plate.
    Last edited by JimLev; 05-17-2018 at 08:17 PM.

  3. #3
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    98 540 6, SC'ed, 16psi
    Nice car. Welcome to the fun of E39 ownership. In for updates.
    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!

  4. #4
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    [deleted]
    Last edited by MotorMouth93; 02-14-2020 at 05:21 PM.

  5. #5
    JimLev's Avatar
    JimLev is offline Artifically Aspirated Moderator
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    Sounds good.
    Just to let you know if you decide remove the flywheel you'll need a special T60 bit. The flywheel has an alignment ring in one of the crank flange bolt holes to keep the flywheel aligned with the crank so the DME knows where it is when the engine is running.
    The ring can fall out when the flywheel is removed so make sure you note what position the flywheel is in when you remove it so it can go back on in the same position.
    If it's not put back on correctly the engine will either not start or just barely run.

    Lets see a pic of that NSX.
    Last edited by JimLev; 05-18-2018 at 08:47 AM.

  6. #6
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    Quote Originally Posted by philly98540 View Post
    Nice car. Welcome to the fun of E39 ownership. In for updates.

    Quote Originally Posted by JimLev View Post
    Welcome to the E39 forum.
    Don't forget to get a new pressure plate and throw out bearing. If you plan on using your old one it will need to be reset as it is a self adjusting pressure plate.

    Thanks!


    I bought the genuine BMW clutch kit from ECS tuning so it includes the friction disk, pressure plate, and throwout bearing, and I ordered a steel pivot pin, alignment tool, and CDV delete to go with it.
    Last edited by MotorMouth93; 08-01-2022 at 11:42 PM.

  7. #7
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    Psst, mods, I think you have to approve his first post. Can't see it as a normal user.
    Nate J.

    (oOO\ (|||)º(|||) /OOo)
    Titanium Silver/Black Nappa Full 07-18-2001 E39 M5 Heritage (BZ99672). 198,000mi+. Increasing daily. Engine rebuild thread.
    (eŌō\ (||||)º(||||) / ōŌe)
    Alpineweiss III/Black Merino Full 03-26-2007 E60 M5 Manual (CX08265). 157,000+. Dead starter -_-

    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). Sold 02-01-2019 at 217,600mi. I regret that. Build Log
    Reliable P.O.S. - Green/gray 1995 Camry V6 LE. 270k mi. Sold for space.

  8. #8
    JimLev's Avatar
    JimLev is offline Artifically Aspirated Moderator
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    Quote Originally Posted by computiNATEor View Post
    Psst, mods, I think you have to approve his first post. Can't see it as a normal user.
    Nate, must be some forum software bug, I've approved it it 3 times now.

    Nice NSX MM93

  9. #9
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    Quote Originally Posted by JimLev View Post
    Nate, must be some forum software bug, I've approved it it 3 times now.

    Nice NSX MM93
    Hmm. I've been experiencing some odd issues lately. Couldn't run searches, my iPad wouldn't connect for a few days...

    Anyways.

    Welcome, MM93!
    Nate J.

    (oOO\ (|||)º(|||) /OOo)
    Titanium Silver/Black Nappa Full 07-18-2001 E39 M5 Heritage (BZ99672). 198,000mi+. Increasing daily. Engine rebuild thread.
    (eŌō\ (||||)º(||||) / ōŌe)
    Alpineweiss III/Black Merino Full 03-26-2007 E60 M5 Manual (CX08265). 157,000+. Dead starter -_-

    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). Sold 02-01-2019 at 217,600mi. I regret that. Build Log
    Reliable P.O.S. - Green/gray 1995 Camry V6 LE. 270k mi. Sold for space.

  10. #10
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    Welcome! You've got a real nice 540i/6 there, and you're definitely approaching it with the right attitude. Unfortunately a lot of Honda owners buy a BMW without thinking about the maintenance and then they complain about how unreliable BMW's are when something breaks.
    1995 525i 5-speed - Thread

  11. #11
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    [deleted]
    Last edited by MotorMouth93; 02-14-2020 at 05:21 PM.

  12. #12
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    Quote Originally Posted by MotorMouth93 View Post
    Thanks for the warm welcome guys! Also are there any keys for these cars that don't have built in keyless entry buttons? I'd much rather just unlock the car manually as the 3-button keys are big and bulky.
    There is a smaller valet key:

    (Thanks, Qsilver7)
    keys.jpg
    Nate J.

    (oOO\ (|||)º(|||) /OOo)
    Titanium Silver/Black Nappa Full 07-18-2001 E39 M5 Heritage (BZ99672). 198,000mi+. Increasing daily. Engine rebuild thread.
    (eŌō\ (||||)º(||||) / ōŌe)
    Alpineweiss III/Black Merino Full 03-26-2007 E60 M5 Manual (CX08265). 157,000+. Dead starter -_-

    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). Sold 02-01-2019 at 217,600mi. I regret that. Build Log
    Reliable P.O.S. - Green/gray 1995 Camry V6 LE. 270k mi. Sold for space.

  13. #13
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    [deleted]
    Last edited by MotorMouth93; 02-14-2020 at 05:21 PM.

  14. #14
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    She looks awesome, very nice!

    Nice work on the headlights. Why the Morimoto Minis? I went with EvoX-R 2.0s as they're basically drop ins, and I used eBay "COB" LED angel eyes, which look nice, IMO.

    - - - Updated - - -

    And your steering wheel re-wrap came out a million times better than mine
    Nate J.

    (oOO\ (|||)º(|||) /OOo)
    Titanium Silver/Black Nappa Full 07-18-2001 E39 M5 Heritage (BZ99672). 198,000mi+. Increasing daily. Engine rebuild thread.
    (eŌō\ (||||)º(||||) / ōŌe)
    Alpineweiss III/Black Merino Full 03-26-2007 E60 M5 Manual (CX08265). 157,000+. Dead starter -_-

    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). Sold 02-01-2019 at 217,600mi. I regret that. Build Log
    Reliable P.O.S. - Green/gray 1995 Camry V6 LE. 270k mi. Sold for space.

  15. #15
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    Last edited by MotorMouth93; 02-14-2020 at 05:21 PM. Reason: My script blocker was doing something to screw up line breaks, but it's fixed now.

  16. #16
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    Very clean work I'm jealous of how nice your interior is and your steering wheel wrap my wife did mine and it looks married great if you get my meaning.

    Where did you get your wrap.

  17. #17
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    Last edited by MotorMouth93; 02-14-2020 at 05:22 PM.

  18. #18
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    Welcome to the forum! Great looking car you have there.

    I did the D2S retrofit as well in my fiance's E46. Did take some trimming but they fit very well and the output is insane.

  19. #19
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    Man, top work on that steering wheel. Might have to have a go when my m wheel gets a bit more worn.

    It's interesting the specs the later 540s came with. Mostly m sport stuff minus the lip spoiler and plus the comfort seats.

    You know my 525i looks pretty much the same from behind hey? Looks like they use the same tip for the exhaust. : p

  20. #20
    geargrinder's Avatar
    geargrinder is offline Having No Trouble Here BMW CCA Member
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    Quote Originally Posted by MotorMouth93 View Post
    I changed the rear main seal as well, rather than change the whole seal plate,
    Yeah I think that's SOP. Replacing the plate is completely unnecc IMO... that never really leaks or has issues. Just do the main seal itself...
    2003 M3CicM6 TiAg
    2002 540iT Sport Vortech S/C 6MT LSD TiAg
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    2014 BMW X1 xDrive28i (wifemobile)

    Former:

    1985 MB Euro graymarket 300SL
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  21. #21
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    Last edited by MotorMouth93; 02-14-2020 at 05:22 PM.

  22. #22
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    You are the second person I have seen to have an NSX and then get an M-Sport 540i E39 IN BLACK & Manual in the past week!

    https://www.youtube.com/watch?v=YiiMehdmUA0 (Unless you're the same person as in the Youtube Channel LOL )
    E39 WhatsApp Chat Gruppe

  23. #23
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    Last edited by MotorMouth93; 02-14-2020 at 05:22 PM.

  24. #24
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    Color banding is fun
    Nate J.

    (oOO\ (|||)º(|||) /OOo)
    Titanium Silver/Black Nappa Full 07-18-2001 E39 M5 Heritage (BZ99672). 198,000mi+. Increasing daily. Engine rebuild thread.
    (eŌō\ (||||)º(||||) / ōŌe)
    Alpineweiss III/Black Merino Full 03-26-2007 E60 M5 Manual (CX08265). 157,000+. Dead starter -_-

    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). Sold 02-01-2019 at 217,600mi. I regret that. Build Log
    Reliable P.O.S. - Green/gray 1995 Camry V6 LE. 270k mi. Sold for space.

  25. #25
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    Last edited by MotorMouth93; 02-14-2020 at 05:22 PM.

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