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

  1. #76
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    98 540 6, SC'ed, 16psi
    Nice progress! Nice to see all new stuff going in. Did you rotate engine over manually a couple revolutions and then recheck timing?
    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!

  2. #77
    Join Date
    May 2018
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    Austin, TX
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    00 M5 | 03 540i | 94 NSX
    [deleted]
    Last edited by MotorMouth93; 02-14-2020 at 05:25 PM.

  3. #78
    Join Date
    Jan 2013
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    orlando, fl
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    2001 BMW 540i 6speed
    wow great job and progress.
    540i 6spd DUDMD tuned-weekend brute, sounds like an M5 throaty V8 "Vtec-ish" cam noise.

    Hummer- 35inch MT's, Adventure offroad package.



    check out my video gear
    https://kit.co/Lv5multimedia/mobile-videographer-set-up

    Best Oil hands down for bmw
    https://www.amazon.com/gp/product/B0...1441c0abde2552

  4. #79
    Join Date
    Feb 2007
    Location
    SoCal
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    My Cars
    2001 BMW 540i 6spd
    Jesus, this is an amazing thread to follow. Wish I had even just a fraction of the skills/knowledge you have working on it. I've got a 2001 540i and need to have the front thrust arm bushings and a strut replaced and the quote I got was for about $1700. I'm sure I could save a few pennies if I only had the DIY skills for it! Looking forward to seeing this thing running again. Thanks for documenting all of it along the way, I love seeing how these things work despite not understanding 99% of the posts hahaha.

  5. #80
    Join Date
    May 2018
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    Austin, TX
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    00 M5 | 03 540i | 94 NSX
    [deleted]
    Last edited by MotorMouth93; 02-14-2020 at 05:25 PM. Reason: removed profanity

  6. #81
    Join Date
    Nov 2018
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    Northern, VA (NoVA)
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    2001 540i/6 Sport
    Subscribed. Awesome work OP. I'm embarking on this road as well albeit with a higher mileage example.

  7. #82
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    May 2018
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    Austin, TX
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    00 M5 | 03 540i | 94 NSX
    [deleted]
    Last edited by MotorMouth93; 02-14-2020 at 05:25 PM.

  8. #83
    JimLev's Avatar
    JimLev is offline Artifically Aspirated Moderator
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    00 540/6, '16 Highlander
    Looks pretty good. You brought your own pallet to the car wash, LOL. Better than setting the parts on the dirty floor.
    I remember that post about a cheap powder coat place, maybe someone will chime in with the info.
    Your replacing the upper oil pan gasket too I hope.

  9. #84
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    Austin, TX
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    00 M5 | 03 540i | 94 NSX
    [deleted]
    Last edited by MotorMouth93; 02-14-2020 at 05:26 PM.

  10. #85
    geargrinder's Avatar
    geargrinder is offline Having No Trouble Here BMW CCA Member
    Join Date
    Mar 2010
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    AndoverRockport MA & Intl
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    E46M3Cic E39.540iT E84X1
    I can't believe the way the distribution housing threaded portion snapped off!?!? WTF!?!? I was having a hard time envisioning what you meant (read the email thread update notice) until I saw the pic.

    Yeah be super careful of the scotchbrite, prob want to hot soapy water wash those solenoids out just in case. Google the immberwebz for stories of good ol' boys who scotchbrited their block decks and heads to clean up gasket residue and varnish and whatnot only to have the scotchbrite dust take the whole new build motor out in no time...
    2003 M3CicM6 TiAg
    2002 540iT Sport Vortech S/C 6MT LSD TiAg
    2008 Audi A3 2.0T DSG (the daily beater)
    2014 BMW X1 xDrive28i (wifemobile)

    Former:

    1985 MB Euro graymarket 300SL
    1995.5 Audi S6 Avant (utility/winter billetturbobattlewagen)


  11. #86
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    Jan 2013
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    orlando, fl
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    2001 BMW 540i 6speed
    i have a guy that powder coats here in orlando, i can get you his info and you guys can work out a deal. he charged me 80 bucks for both covers in crinkle black.


    Quote Originally Posted by MotorMouth93 View Post
    I just keep the pallet in the back of the truck permanently LOL, it comes in handy more often than you'd think, in this case it kept the aluminum parts from having to touch the concrete and potentially damage the sealing surfaces.

    Yup, new upper and lower oil pan gaskets are waiting to be installed. I'm going to get the lower timing cover and rear main seal plate bolted back up first (waiting on new gasket washers for the RMS, should be here Friday) before I do the oil pan gaskets. I'm thinking that it's better to do those first so I have a flat surface to seal the oil pan to, so I can just add a bit of grey RTV in the 4 seams and then button it up all the way around in one go. I don't like the method of putting the oil pan on first then bolting the lower timing cover/RMS plate into the corner, seems like a good way to damage the gasket and/or end up with slight oil leaks.
    540i 6spd DUDMD tuned-weekend brute, sounds like an M5 throaty V8 "Vtec-ish" cam noise.

    Hummer- 35inch MT's, Adventure offroad package.



    check out my video gear
    https://kit.co/Lv5multimedia/mobile-videographer-set-up

    Best Oil hands down for bmw
    https://www.amazon.com/gp/product/B0...1441c0abde2552

  12. #87
    Join Date
    Mar 2012
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    98 540 6, SC'ed, 16psi
    http://boneheadperformance.com

    These guys did a great job on mine. Proper pre bake out and such. Highly rated hard working guys there. Likely going to be pricey with shipping and all though...
    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!

  13. #88
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    00 M5 | 03 540i | 94 NSX
    [deleted]
    Last edited by MotorMouth93; 02-14-2020 at 05:26 PM.

  14. #89
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    Quote Originally Posted by MotorMouth93 View Post
    I would be very interested in getting his information, that is a great price.

    ill get it when i get out of the office today and shoot you a message. this is how they came out



    540i 6spd DUDMD tuned-weekend brute, sounds like an M5 throaty V8 "Vtec-ish" cam noise.

    Hummer- 35inch MT's, Adventure offroad package.



    check out my video gear
    https://kit.co/Lv5multimedia/mobile-videographer-set-up

    Best Oil hands down for bmw
    https://www.amazon.com/gp/product/B0...1441c0abde2552

  15. #90
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    May 2018
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    Austin, TX
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    00 M5 | 03 540i | 94 NSX
    [deleted]
    Last edited by MotorMouth93; 02-14-2020 at 05:26 PM.

  16. #91
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    Apr 2009
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    NW Ontario
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    '05 M3, '02 525iT
    Just read through this thread, great work so far! The car looks super clean, a classic example of the beauty of the E39. I particularly like the steering wheel rewrap you did. I tried redying my wheel and it never turned out as well as I'd hoped, and I never thought of a DIY rewrap before.

    Good luck on the rest of your engine rebuild and install, I look forward to seeing updates!

  17. #92
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    Last edited by MotorMouth93; 02-14-2020 at 05:26 PM.

  18. #93
    JimLev's Avatar
    JimLev is offline Artifically Aspirated Moderator
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    Looks good. Will look even better after you clean off the grease and dirt of the top of the upper oil pan.

  19. #94
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    1995 525i/5
    Did you intentionally leave the front crank seal off for now? I usually install a new front seal into the timing cover before reinstalling it, that's worked out nicely over the last 18 guide jobs I've done.
    1995 525i 5-speed - Thread

  20. #95
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    Last edited by MotorMouth93; 02-14-2020 at 05:26 PM.

  21. #96
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    540 m sport
    Did you still use timing tools (like the timing blocks that sit on he camshafts) when the engine is out the car in order to change timing guides? Im looking at buying an engine soon to rebuild during the winter. How much easier is this job doing it outside of the car?

  22. #97
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    Quote Originally Posted by upbeatgfx View Post
    Did you still use timing tools (like the timing blocks that sit on he camshafts) when the engine is out the car in order to change timing guides? Im looking at buying an engine soon to rebuild during the winter. How much easier is this job doing it outside of the car?
    Yeah, you still need the timing tools, the engine's timing procedure doesn't change when it's outside the car...

    I wouldn't say it's much easier overall. Yes, you have better access, but to pull an engine out and then put it back in, that's a heck of a lot more work and comes with the risk of breaking more stuff. The only time it makes sense to do a job like this with the engine out of the car is if you already have to have the engine out, like in the OP's case.
    1995 525i 5-speed - Thread

  23. #98
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    Last edited by MotorMouth93; 02-14-2020 at 05:26 PM.

  24. #99
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    Last edited by MotorMouth93; 02-14-2020 at 05:26 PM.

  25. #100
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    Last edited by MotorMouth93; 02-14-2020 at 05:26 PM.

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