95 540i/6 "While-I'm-in-There" Resto

[Mama Tried]

All purtyed up.

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[circuit.heart]

Ever consider tinting you front and rear markers to match the smoked headlights? I'm very much considering it, the smoked headlights look better every time I see a car with them.

[Mama Tried]

Ever consider tinting you front and rear markers to match the smoked headlights? I'm very much considering it, the smoked headlights look better every time I see a car with them.

I'd like too - just have to figure out if they can be decently tinted or if they need to be bought that way. Really stands out against the Oxford Green how bright the clears are compared to headlights.

[circuit.heart]

Depo side markers can be bought in smoke for front and rear, but cheaper just to tint what you got with Lamin-X. That was my plan as well, was going to film all six front lights to protect the lenses from the BS I subject them to.

[botticelli]

Absolutely stunning!

[Johal E32]

Wow, gorgeous ride! We should meet up sometime and do a photoshoot with my calypso Dinan 5

[Mama Tried]

Raining hard here in norcal today (end of times for sure), so thought I'd update recent stuff while waiting for more parts from what should have been just a simple one-afternoon control-arm replacement. Attached are photos and the tl:dr version is stuff just keeps popping up while I'm in there!

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Absolutely stunning!

Thanks! Project Santa Cruz nice and storm coming your way later today!

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Wow, gorgeous ride! We should meet up sometime and do a photoshoot with my calypso Dinan 5

Red and Green - love it! December page for e-34 calendar! Lets do it!

[circuit.heart]

Raining hard here in norcal today (end of times for sure), so thought I'd update recent stuff while waiting for more parts from what should have been just a simple one-afternoon control-arm replacement.

That rain was a godsend, washed all of my cars baby-butt clean.

I should've dropped by after the track day last weekend to say hi, we were limping the car home from Sonoma though lol. Next time, use a ball joint separator to pop the ball joints out, it's much less destructive than pickle fork!

[Mama Tried]

Well all done for now. (ha!) Not sure how i'd rate job pleasure - somewhere up there with power steering and getting my hand behind left headlight to work in that area! Anyhow it does look good and what a difference! Someone said that shocks and springs are all that, but arms and bushings are often really the main issue. Sure seems so to me, and as Koni's aren't leaking, etc., probably can hold off on that for a bit.

I couldn't find much if anything in Bentley re 540i support arm set-up which holds thrust arm and sway bar, so had to piece some info together for that. Otherwise just time and first-time repair learning.

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That rain was a godsend, washed all of my cars baby-butt clean.

I should've dropped by after the track day last weekend to say hi, we were limping the car home from Sonoma though lol. Next time, use a ball joint separator to pop the ball joints out, it's much less destructive than pickle fork!

Next time we'll connect - maybe some events in east bay coming up. Yep - got the separator late but was a godsend for the tire-rod ends! Hope the car's done limping!

[Mama Tried]

Finally got the "blind plugs" for bell housing. Still not sure what this set-up is all about, but plugged them anyway. Not cheap at $40 bucks for all of them but couldn't find any after-market.

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[Mama Tried]

On to rear windows which were in-op. Standard stuff - drill rivets, etc. Vapor barrier removed nicely and no inside rust. Window slides so degraded the plastic keepers crumbling and whatever "grease" was in there had turned to glue which of course bent the regulators. Going BOE as I don't want to do this job again.Debating whether to do fronts, though both sides currently work.

Motors worked to lower windows, but did notice oil seepage out of the cable covers - maybe just normal wear? I'll take the chance and reuse motors as comments I've read say motors rarely fail.

I'll try to clean and lube window slides as best I can but really don't want to remove windows.

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[Mama Tried]

With regulators under repair of course need to resto door cards. I appreciate any insights!

Resources for card parts? Need a few of the black panel-clip anchors - there's two kinds it seems - couple uppers and the majority lower style.
Also those tiny rod grommets - I could turn them to direction of pull, but rather replace. Maybe just have to prowl hardware store or Grainger I guess.
Recommendations on adhesives for fabric and anchors? As common, fabric pulling away at top - adhesive failure and fabric shrinkage.

Thanks so much for any advice! - a lot of the DYI's are old and have busted links, etc. CarID has some stuff I could make fit, too I guess.

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[a777fan]

Whoah… there are OE plugs for all the holes in the bellhousing!?!!

[Mama Tried]

Whoah… there are OE plugs for all the holes in the bellhousing!?!!

Crazy right? And the large one is called "Oil Level Indicator Cover". Go figure. Probably the second most bizarre BMW thing after the cabin filter location! Took me way too long to find them, too. But those holes always bugged me a bit as it seemed decidedly out of Teutonic character to leave them open like that! At least they're not cheap.

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[Mama Tried]

Cabin filter you say? 540i took about an hour. e39? Five minutes. Admittedly it was first time. But still. (Old filter was from 02. Nice!) I did spy the little fire-starter box in the cavity and made sure it was really clean. Looked decent but who knows as it was way out of reach from filter access. I guess access only through firewall below squirrel cages. Now that looks like a fun job!

After all that still trying to find correct replacement gas piston for the janky glove box set-up! Best I can figure out is 7.5" on center and 25n pressure. Also heat distribution channel to passenger legs has busted securing tabs from last person in there so it flops about a bit. Add it to the list!

Cleaned A/C brain and place where it lives. Re-taped harnesses where exposed. Found the air-bag wire severely pinched and wonder if that's why light is perpetually lit...probably not.

Interior work - bah! I'll never complain about engine/suspension work again.

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[jehu]

Found the air-bag wire severely pinched and wonder if that's why light is perpetually lit...probably not.

Interior work - bah! I'll never complain about engine/suspension work again.

a 540 I bought once came with one of these. An airbag bypass

https://www.aliexpress.com/item/4000263346262.html

if the seat occupancy sensor is triggering your SRS light maybe something like this can fix it.. they apparently also make an emulator if that would actually be the one to use..

[Mama Tried]

Finally got the window regulators and motors sorted, and door cards refurbed. Removed both mirrors for clean and lubrication and now they move and fold without grinding like a peppermill

Door cards look fair, but as I didn't recover the lower areas, the pleated leather inserts remain not so pleated given shrinkage over the years. Same for some of the edge areas puckered a bit in order to gently re-stretch material over the edges. Perhaps it will relax a bit over time with doors shut. Lot of work on the reverse sides to re-secure clip mounts, strengthen weak or split areas, etc.

New fabric for the top bars as they were badly shrunk. Re-dyed a few areas and though all four have some variation, they're good enough. Upholster work was significant along with new rear regulators & motors, tweeter-surrounds and fixings. Front regulators and motors were operational, and likely against better judgement decided to just to clean, grease and adjust them. The work fine for now.

Front doors had previous fiddlers and a fair amount of work just to correct things poorly repaired. But all good, and on to carpet cleaning, re-install sport seats and find a place for the comforts other than the living room which is not a popular place of repose currently. Go figure!

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[a777fan]

Its a shame that the door card leather shrinks like that. Looks more and more like a pre-95 each day! mine is similarly affected.

Great work!

[jehu]

Finally got the "blind plugs" for bell housing. Still not sure what this set-up is all about, but plugged them anyway. Not cheap at $40 bucks for all of them but couldn't find any after-market.

Blind Plugs Installed, 95 540i.jpg

Ever had a slave cylinder blow out? I have ... squirted a bunch of clutch fluid into the bell housing... maybe these are to control the exit of such a fluid failure... pull the plugs and drain them when you're ready?

[Mama Tried]

Its a shame that the door card leather shrinks like that. Looks more and more like a pre-95 each day! mine is similarly affected.

Great work!

Thanks! I really wanted to refurb those pleated inserts as most of them look "dolphin smooth" nowadays (apologies to Abraham from WD).

But with the e21 parts list increasing figured I ought to wind back a bit on the 540 as tally for "the green whale" (as its affectionately called by some in the household) runs up against impending college expenses. Sheesh who needs college anyways? She informed me that it will now take until the 2040's for BAT to catch up to the car now. Plus I got from a member a really nice, refurbed e36 steering wheel which didn't go un-noticed around the casa either. It has a great feel and always loved the 3-spoke design. Still have the OEM one, though.

(thanks again for notes on window motor stops!)

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[Mama Tried]

Ever had a slave cylinder blow out? I have ... squirted a bunch of clutch fluid into the bell housing... maybe these are to control the exit of such a fluid failure... pull the plugs and drain them when you're ready?

Ha! Good as explanation as any that I've found! On one of my very first cars - an Audi 100LS (like the one pictured) I was driving on Cottman Ave in north philly and the trans fluid line popped off (common I hear) and sprayed oil all over exhaust. The car turned into a Bond-like smoke screen feature and it positively billowed everywhere stranding me and putting me on the receiving end of clever insults from the good citizens of philly behind me. Thank goodness I wasn't in a Santa suit (philly inside joke). That car was a bit of a nightmare as I recall. OK a lot of a nightmare.

Speaking of vestigial BMW parts, when cleaning the door crevices I found this part rattling around in the crud (BOE 1391315). As best I can tell from a few posts it's some kind of magnetic window attachment to set off alarm if window is broken. As my alarm has a mind of its own at times, I hope this isn't the reason...no probably not.

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[Mama Tried]

Much has been documented on windows, with threads in these pages was very helpful. From my experience, two key areas - attaching regulators to window rails, are worth a mention.

The advice to first insert the plastic regulator glide into the bottom window rail with hair-pin clips already installed was spot-on. Sounds counterintuitive but it really made attaching the regulator glide-points much easier.

Second, advice on how to "pop-in" the two glide points (rounded knobs on the regulator arms) suggest choices of pliers, vice grips, clamps, etc., and rightly cautioning against damage to rails or glass. It can be awkward getting everything lined-up with enough access for sufficient leverage to "pop" them into the glides, all while managing the "squeeze" pressure.

I found that a 2" hobby c-clamp the best tool to use. Small enough for access, easy to adjust and control clamping pressure to turn it until that loud pop informs it's seated. Small beer, I know, but this is a point where lot is on the line - like glass, regulator arms or the rails.

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[93FIM5]

Love the work being done, would of suggested our pin pads as a while you're in there thing as it brings the E34 up to date with the more modern cars that have them as stock. More of the green whale!

[Mama Tried]

More from the green whale! Sport seat-back repairs the final work needed and ready to go! Nice of BMW to use scraps of M fabric on the original build - aspirational marketing ploy I suspect. Now to get the comforts out, clean carpet and install.

Of course the plastic trim on all of them is replete with broken tabs, gouges and an odd yellowish tinge. Bought a couple cans of Accumatch pergament interior dye to hopefully cobble together a reasonably matching set of plastics.

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For anyone interested, below is tag for driver Sport Seat with powers, heat, memory

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