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Thread: New to me '03 530i Sport

  1. #26
    Join Date
    Sep 2014
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    North OC, CA
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    01 M5 TiAg/M1SW
    Quote Originally Posted by Twistytee View Post
    Well it was a good news/bad news weekend for the 530i. Good news was the headlamp resto turned out great and while waiting for a new bumper gasket to show-up, I headed out to the pick-a-part and got a new driver’s side brake duct, gas door hinge, spare set of heated washer jets, a tail light harness connector, and some random trim pieces. While cleaning-up the tail light area, I noticed I had corrosion in the passenger side harness. Someone had been in here before, cut the plastic connector apart and jammed it back together.

    drivers side:

    passenger side connector:

    My battery is new, AGM, and properly vented for the blow-off valve, so I’m guessing this was water intrusion through the tail light gasket. The light still works and I’ve installed a replacement connector, but I may need to replace this lamp and gasket if I continue to get error messages.

    I also noticed while working on the bumper cover and related duct work that replacing my oil pan gasket needs to be moved up the priority list. So a few cosmetic projects including the headliner will be put on hold while I address this. What else should I tackle while the subframe is dropped? I’m assuming motor mounts although mine still look good - Lemforder ok or is there a better option? I will probably do the oil filter housing gasket at the same time. VCG was recently done and someone was in there before and replaced the two hoses and clamps on the PS reservoir that are prone to leaking.
    I had the same issue with the taillight connectors. It’s due to old taillight gaskets. Replace them ASAP, as it’ll only get worse. I ended up replacing the entire taillight.

    I just finished a major service, which included dropping the subframe. I suggest taking a look at the following items:
    - Bimmerworld reinforced oil pump nut w/ safety wire. The M54B30 can break its oil pump if driven hard at high RPMs.
    - Power steering rack hoses
    - Power steering rack tie rod boots/gaiters. Inspect them carefully for tears.
    - If you’ve ever wanted a bigger sway bar, now is the best time to do it. I highly recommend the Eibach sway bars.
    - Dawn dish soap, for cleaning things. Dawn sticks to the grease and breaks it down. It works better than brake clean because it doesn’t evaporate.

    Its also a great time to inspect the suspension. The control arms, the tie rods, the shocks, the brakes, etc. With my recent subframe down, transmission out service, I replaced the entire front suspension, the flywheel/clutch, the transmission itself, and serviced the driveshaft. I also did brakes at all four corners, stainless steel brake lines, and rear shocks and springs.
    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.

  2. #27
    Join Date
    Jun 2016
    Location
    North Carolina
    Posts
    1,249
    My Cars
    03 525it/5, 1967 GTO
    Good call on the oil pump nut. My steering rack looks good and the low pressure lines were replaced. Hoping the high pressure line is still good. I completely redid the suspension on my other cars including powder coating the control arms and brakes. Hoping to get some more miles out of the current set-up before going down the upgrade path. Thanks for the dawn tip. I definitely need a good degreasing of the lower engine. Sounds like you’ve been busy!

  3. #28
    Join Date
    Jun 2016
    Location
    North Carolina
    Posts
    1,249
    My Cars
    03 525it/5, 1967 GTO
    Got a good look under the rear of the car this weekend. Looks like I have a leaking diff output seal on the driver's side. Anyone have experience replacing the seal with the diff still on the car or do I need to drop it?

  4. #29
    Join Date
    Sep 2014
    Location
    North OC, CA
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    3,327
    My Cars
    01 M5 TiAg/M1SW
    Quote Originally Posted by Twistytee View Post
    Got a good look under the rear of the car this weekend. Looks like I have a leaking diff output seal on the driver's side. Anyone have experience replacing the seal with the diff still on the car or do I need to drop it?
    My seals look just slightly damp; there’s some dark spots. However, unless it looks wet, I wouldn’t worry about it. I do believe removal is required.
    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.

  5. #30
    Join Date
    Jun 2016
    Location
    North Carolina
    Posts
    1,249
    My Cars
    03 525it/5, 1967 GTO
    It looks like it started recently but seeping enough to throw some gear oil against the underbody above the axle joint. I’ve replaced them before on other cars but usually in combination with dropping the diff for pinion seal work. The pinion and passenger side seals are dry so I may just monitor to see if it gets any worse.

  6. #31
    Join Date
    Dec 2009
    Location
    Manchester, NH USA
    Posts
    4,728
    My Cars
    2003 530i/5 2008 Hemi WK
    Once you go black, you never go back.

  7. #32
    Join Date
    Sep 2014
    Location
    North OC, CA
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    3,327
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    01 M5 TiAg/M1SW
    Quote Originally Posted by Twistytee View Post
    It looks like it started recently but seeping enough to throw some gear oil against the underbody above the axle joint. I’ve replaced them before on other cars but usually in combination with dropping the diff for pinion seal work. The pinion and passenger side seals are dry so I may just monitor to see if it gets any worse.
    Are you sure the axle CV joint boot isn’t split?
    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. #33
    Join Date
    Jun 2016
    Location
    North Carolina
    Posts
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    My Cars
    03 525it/5, 1967 GTO
    CV boot is fine and intact. Lube is definitely coming from the output shaft mount.

  9. #34
    Join Date
    Jun 2016
    Location
    North Carolina
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    03 525it/5, 1967 GTO
    Started digging into my oil leak issue and decided to drop the subframe and have a go at the gasket.

    Subframe and oil pan covered in dirt, grease and oil

    Untitled by Twistytee, on Flickr

    oil pan sensor was dripping in lube

    Untitled by Twistytee, on Flickr

    Topside of subframe job

    Untitled by Twistytee, on Flickr

    ”while you are in there” these don’t look so good

    Untitled by Twistytee, on Flickr

    popped off the OFH and as suspected after 15 years the gasket was pretty brittle. Oil everywhere

    Untitled by Twistytee, on Flickr

    a bit of aluminum safe degreaser and some elbow grease later

    Untitled by Twistytee, on Flickr

    oil pan and gasket back on but still need to bolt-up subframe and tackle the cooling system. Hope to have it back on the road this weekend but also got sidelined with a torn CV boot on one of the Audi half shafts. Darn things always blow at the most inopportune time.

  10. #35
    Join Date
    Sep 2014
    Location
    North OC, CA
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    01 M5 TiAg/M1SW
    Yep, sounds about right. The subframe is a royal PITA because its greasy work on your back (I'm not lucky enough to have a lift).

    Despite that, it's not terribly difficult. Mostly just bolts and more bolts, thankfully.
    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.

  11. #36
    Join Date
    Jun 2016
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    North Carolina
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    03 525it/5, 1967 GTO
    Yep. Difficulty not high but sure is a ton of work to access it and rebolt. What’s the current consensus on the CDV delete? Remove and just bend/connect the hard pipe or substitute a valve with widened guts?

  12. #37
    Join Date
    Jun 2016
    Location
    North Carolina
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    03 525it/5, 1967 GTO
    Been awhile since I've updated this thread. I keep working through my project list.

    Since the last update:

    Installed a SSK, weighted ZHP knob and did the CDV delete

    Installed a tilt euro arm rest w/ storage tray

    Took it to the body shop and got my cracked windshield replaced and rear bumper cover painted

    Finished realigning my front bumper and repaired the fog light brackets and brake ducts.

    Overhauled the cooling system including M5 radiator, aluminum pulleys, new pump, new fan clutch & hoses

    Overhauled the sound system including new amp, separates upfront with passive crossovers, coaxials in the rear and 10" free-air subs hanging from the rear deck

    Pulled the interior apart to recover the rear parcel shelf, headliner and pillar trim (went with an anthracite material for headliner similar to what Audi/VW uses which is requiring me to dye all the grey plastic trim black). Hoping to get everything back in the car this weekend.

    Decided while the interior was apart I'd replace the rear shocks/struts with Koni Yellows (magic carpet ride with OE sport springs)

    Did the seat twist repair on both the drivers and passenger side

    New inner & outer tie rods

    M5 rear sway and new Meyle links

    Outstanding To Do Items:

    Rebuild & powder coat my brakes

    New tires & an alignment

    New trunk struts

    Get it to a PDR guy for the body dings

    Still need to get my cluster up to Blacknight so I can get the pixel repair done. Hoping to check out his latest wagon project while I'm at it.


    Untitled by Twistytee, on Flickr

    Untitled by Twistytee, on Flickr

    Untitled by Twistytee, on Flickr

    Untitled by Twistytee, on Flickr

    Untitled by Twistytee, on Flickr

  13. #38
    Join Date
    Sep 2014
    Location
    North OC, CA
    Posts
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    My Cars
    01 M5 TiAg/M1SW
    Good work!
    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.

  14. #39
    Join Date
    Jun 2016
    Location
    North Carolina
    Posts
    1,249
    My Cars
    03 525it/5, 1967 GTO
    Finished my headliner and rear parcel shelf project today. Converted from the standard grey/platinum to a textured anthracite. It is darker but I’m pretty happy with the results. Hardest part was getting the sunroof glass back in. Lining up those front pins and screws took a lot of patience. But it’s all together and sitting flush. I used some RV dry slider lube for the channels. Worked well and hopefully won’t attract dirt. Broke one of the child seat anchor trim pieces for the back panel. Those things get brittle with age and the clips are fragile. I’ll get it replaced at some point. You can see my Mauritius E36 peeking out the rear window. Just put a new softop on it a few weeks ago. Getting a little better with fabric and upholstery jobs working between two cars if this vintage.

    Before:

    Untitled by Twistytee, on Flickr

    After:

    Untitled by Twistytee, on Flickr

    Untitled by Twistytee, on Flickr

    Untitled by Twistytee, on Flickr

  15. #40
    Join Date
    Sep 2014
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    North OC, CA
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    01 M5 TiAg/M1SW
    Looks great! That material looks like it has a good amount of plushness to it; perhaps even more than OEM?
    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.

  16. #41
    Join Date
    Jun 2016
    Location
    North Carolina
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    03 525it/5, 1967 GTO
    Thanks! The microsuede on the rear shelf is thicker, which made fitting the C pillars more of a challenge. Supposedly the headliner material that I used is 1/8” foam backed but it wasn’t as thick as the microsuede. I’ve read that BMW used something closer to 1/16” foam backed fabric but I’ve never been able to verify that.

  17. #42
    Join Date
    Jun 2016
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    North Carolina
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    03 525it/5, 1967 GTO
    Started end of summer detail. Dropped front bumper to realign mounts and pulled the body color trim to clean out dirt and pollen. Mechanically speaking the 530i is running smooth and GTG. Clean 530i is a happy 530i


    Untitled by Twistytee, on Flickr

    Untitled by Twistytee, on Flickr

    Untitled by Twistytee, on Flickr

  18. #43
    Join Date
    Oct 2016
    Location
    Norton Massachusetts
    Posts
    76
    My Cars
    2003 530i M-sport
    Exactly. Clear coat on mine, abject failure. Not my favorite style either: I plan to buy some 32s pretty soon and get rid of my 42s with their fake bolt heads all round. Then somebody else can refinish them.

  19. #44
    Join Date
    Nov 2011
    Location
    Milwaukee, WI
    Posts
    962
    My Cars
    '03 530i/5sp Sport
    Fake bolt heads on style 42s? Mine have 19 titanium 8mm x1.0 XZN screws holding the two pieces together.

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