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Thread: Arson's 2001 540it Build Journal

  1. #1
    Join Date
    Nov 2020
    Location
    Los Angeles
    Posts
    49
    My Cars
    01 540it

    Arson's 2001 540it Build Journal

    2001 540it (Auto)
    Titanium Silver Metallic | Black Interior
    M sport package
    Cold Weather Package
    135k miles Clean title
    95 M3 - Sold
    00 330ci - Sold
    04 M3 - Sold
    01 540it - Daily

  2. #2
    Join Date
    Aug 2016
    Location
    Virginia,USA
    Posts
    2,971
    My Cars
    528i, 525iT, M5, x5 4.8
    Current Garage Highlights
    2005 X5 4.8is Le Mans Met Blue
    2003 525iT TiSilver
    2002 M5 TiSilver
    1998 528i KASCHMIRBEIGE METALLIC (301) (Goldie)

    Former Garage Highlights
    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

  3. #3
    Join Date
    Oct 2016
    Location
    Atlanta
    Posts
    335
    My Cars
    2001 540iT
    so what kind of build are you going to do?

  4. #4
    Join Date
    Nov 2020
    Location
    Los Angeles
    Posts
    49
    My Cars
    01 540it
    Purchased with the below back in January-ish 2021

    2001 540i Wagon
    WBADR63431GN91729
    M Sport Package (Not M Sport)
    Cold Weather Package
    130k miles
    Clean title

    Purchase Thread: https://www.bimmerforums.com/forum/s...ell-maintained

    All stock except the following:

    M5 gauge cluster - all coding done properly and all functions work 100% M5 Steering Wheel M5 replica Front bumper (very nice fit) LED halo bulbs Euro center armrest (with storage) OE painted Side trim wrapped in 3M satin black vinyl ECS Black grills Borla XS 3" stainless muffler with nice 4" Stainless slash cut tip Front Cross-Drilled Rotors ECS Stainless Brake Lines Eibach sport front springs (just to even out the stance)

    Updated Audio system:

    Alpine 2-DIN in dash head unit w/ Carplay, Android Auto, and steering wheel controls Alpine PDX 5 channel amp Alpine type X 6.5” component front speakers JL Audio 10" subwoofer in custom enclosure above battery

    Maintenance (all receipts are on file):

    Transmission replaced with brand new by BMW at 70k miles New aux fan Full cooling system re-fresh (rad, hoses, reservoir, water pump, etc) Trans cooler hoses Power steering lines and reservoir Timing Chain, guides, tensioner Rear air bags (air springs) New Climate control panel, New Battery Front thrust arms New lower control arms New Front sway bar links New Front Sway bar bushings New Front center link and pitman arm New tie rod ends New OE Sachs front struts New front rubber spring isolators New front upper strut mounts New rear ball joints New rear upper control arms and guide links New rear sway bar links New rear integral links New Bilstein rear shocks New OE engine mounts New trans mounts New Driveshaft center bearing New driveshaft Guibo New valve cover gaskets New Valley pan and intake manifold gaskets New lower oil pan gasket Brake booster replaced Brake fluid flush Brake pads New Cabin filters New plugs New battery New alternator New coils Upper timing cover gaskets Headlight adjusters replaced and lights polished Automatic headlight retrofit (all OE parts) Compustar remote start 17” Style 66 staggered wheels with Goodyear tires w/ about 5k miles 235/45/17 front 255/40/17 rear Weathtech floormats for the front
    Attached Images Attached Images
    95 M3 - Sold
    00 330ci - Sold
    04 M3 - Sold
    01 540it - Daily

  5. #5
    Join Date
    Nov 2020
    Location
    Los Angeles
    Posts
    49
    My Cars
    01 540it
    - OEM M5 (Style 65) rims
    - New Michelin Pilot Sport 4s
    - Ceramic Coated Rims w/Adam's Polish

    - Genuine M5 side door moulding
    - New OEM M5 Floor Mats

    - New OEM BMW Battery
    - Oil Change and service 135k

    IMG_9128.jpgIMG_9129.jpgIMG_9389.jpgIMG_9444.jpg
    95 M3 - Sold
    00 330ci - Sold
    04 M3 - Sold
    01 540it - Daily

  6. #6
    Join Date
    May 2019
    Location
    Detroit , Michigan
    Posts
    69
    My Cars
    2002 525i Touring
    Man I want Style 65s so bad

    that is a very healthy service list too
    Joey

    2002 525i Touring M5T Project
    2002 Subaru Wrx Sti Touring Project
    2013 VW Touareg TDI EPA Nightmare

    Build log
    https://www.bimmerforums.com/forum/s...M5T-Conversion

  7. #7
    Join Date
    Feb 2014
    Location
    Alexandria, VA
    Posts
    8,664
    My Cars
    ‘01 540’00 528T’03 525T
    Quote Originally Posted by JN Garage View Post
    Man I want Style 65s so bad

    that is a very healthy service list too
    They’re nice, but they’re heavy. I have two sets of them, not using one of them right now, gunna paint them, what color? I don’t know yet. One set is OEM shadow chrome, the other set, I stripped and am almost ready for powder coat. Thinking of a Titanium shadow chrome, should look good on my green wagon? Not sure yet.
    Set the controls for the heart of the sun

  8. #8
    Join Date
    Nov 2020
    Location
    Los Angeles
    Posts
    49
    My Cars
    01 540it
    - OEM MTech front bumper (w/fresh paint)
    - New OEM front bumper moldings
    - New OEM front headlight squirters

    - New OEM Mtech rear bumper (w/fresh paint)
    - New OEM rear bumper moldings
    - New OEM rear bumper PDC sensors
    - New OEM bumper rubber moldings
    - OEM M5 exhaust install (Driver side only)

    - OEM M5 side mirrors (w/fresh paint)
    - OEM drivers side switch pannel + passenger module (auto dip + auto fold)

    - New Mann air filter (136k)
    - New Mann pollen filters (136k)

    Image from iOS (11).jpgImage from iOS (12).jpg
    95 M3 - Sold
    00 330ci - Sold
    04 M3 - Sold
    01 540it - Daily

  9. #9
    Join Date
    Nov 2020
    Location
    Los Angeles
    Posts
    49
    My Cars
    01 540it
    137k Miles

    - New serpentine drive belt (Continental)
    - New a/c belt (Continental)
    - New idler pulley, tensioner pulley, tensioner (both serp and a/c sides)
    - Coolant flush OEM Coolant + Distilled water

    - M5 metal front brake duct housings
    - M5 rear calipers
    - New OEM Brake Pads (Rear)
    - New Zimmerman rotors (Rear)
    - New anti-rattle brake clips (Rear)
    - New OEM BMW Center Caps x4

    Image from iOS (14).jpgImage from iOS (13).jpg
    Last edited by Arson8; 12-17-2021 at 07:53 PM.
    95 M3 - Sold
    00 330ci - Sold
    04 M3 - Sold
    01 540it - Daily

  10. #10
    Join Date
    Jun 2012
    Location
    Mundelein, IL
    Posts
    831
    My Cars
    840Ci/6 528iT Europa TCS
    Your car looks really great and your modifications are tastefully done. I had a set of imitation style 62s. They were really heavy and they're gone.

  11. #11
    Join Date
    Nov 2020
    Location
    Los Angeles
    Posts
    49
    My Cars
    01 540it
    Quote Originally Posted by rjbaren View Post
    Your car looks really great and your modifications are tastefully done. I had a set of imitation style 62s. They were really heavy and they're gone.
    Thank you for the comment! My builds are always the OEM+ type, where I try to restore/make things better than factory.
    95 M3 - Sold
    00 330ci - Sold
    04 M3 - Sold
    01 540it - Daily

  12. #12
    Join Date
    Dec 2016
    Location
    Canton, Ohio
    Posts
    607
    My Cars
    97 528i
    Quote Originally Posted by Arson8 View Post
    ....
    - M5 metal front brake duct housings.....
    car looks incredible Arson...! Love the "no expense spared" approach too

    Question though....and you surely already are aware of this..... Did you ventilate the insert in the front bumper (between the foglights) when you fit the bumper, leave it out, or did you use the euro grille insert..? All the US cars (incl. M5...) have panels on the outboard ends that block off the brake cooling ducts...

    My euro M-sport touring had the panel ventilated all the way end-to-end which left the inlets to the brake ducts open and made them functional.

    EDIT: this portion here... This area (both left and right sides) was open and not blocked off. The US cars have a solid panel there that directly blocks the air coming into the brake cooling ducts. Again...I'm sure you already know all this shit.

    my vin was GU96619 if you want to search any euro spec parts. you prob don't need this either...lol

    IMG_20160522_152836375.jpg
    Last edited by adm750; 12-28-2021 at 08:55 AM.
    "two wrongs don't make a right...only three lefts do...."
    '79 Euro 635csi - gone and regretting it...
    '89 gsxr-750 - former traffic knife
    '97 528i sedan - holding on strong...(just sold after 16 years of ownership - sad day)
    '03 Euro 525it - something about a famous dolphin.....

    '06 Mercury Grand Marquis (don't ask....it gets the job done....)
    '84 Specialized Allez - full Campagnolo Super Record
    '99-ish Cannondale CAAD4
    "Stinky" - Kona Stinky Five
    '86 528e
    2008 E70 X5 3.0


  13. #13
    Join Date
    Nov 2020
    Location
    Los Angeles
    Posts
    49
    My Cars
    01 540it
    Front Msport bumper is vented. In other words, the brake ducts are completely functional

    Quote Originally Posted by adm750 View Post
    car looks incredible Arson...! Love the "no expense spared" approach too

    Question though....and you surely already are aware of this..... Did you ventilate the insert in the front bumper (between the foglights) when you fit the bumper, leave it out, or did you use the euro grille insert..? All the US cars (incl. M5...) have panels on the outboard ends that block off the brake cooling ducts...

    My euro M-sport touring had the panel ventilated all the way end-to-end which left the inlets to the brake ducts open and made them functional.

    EDIT: this portion here... This area (both left and right sides) was open and not blocked off. The US cars have a solid panel there that directly blocks the air coming into the brake cooling ducts. Again...I'm sure you already know all this shit.

    my vin was GU96619 if you want to search any euro spec parts. you prob don't need this either...lol

    IMG_20160522_152836375.jpg
    95 M3 - Sold
    00 330ci - Sold
    04 M3 - Sold
    01 540it - Daily

  14. #14
    Join Date
    Nov 2020
    Location
    Los Angeles
    Posts
    49
    My Cars
    01 540it
    Started on my dual exhaust conversion. Ultimately I decided to go with the stock M5 cans (these can be picked up cheap) for a more authentic look. The conversion was done the "Speed Academy" way, which can all be found on YouTube.

    - Replaced battery cables with factory M5 ones
    - M5 side cut
    - M5 exhaust cans
    - M5 battery box
    - Custom box welded in with room to fit battery box and SLS pump.
    - Custom box was undercoated, seam sealer was applied to welds, painted with high temp silver and satin clear coat

    Next steps are to finish sealing everything up, mount the bumper and weld up the pipes.

    Image from iOS (13).jpgImage from iOS (14).jpgImage from iOS (15).jpgImage from iOS (16).jpgImage from iOS (17).jpg
    95 M3 - Sold
    00 330ci - Sold
    04 M3 - Sold
    01 540it - Daily

  15. #15
    Join Date
    Jun 2016
    Location
    North Carolina
    Posts
    1,239
    My Cars
    03 525it/5, 1967 GTO
    Nicely done.
    “She’s the last of the V8’s, she sucks nitro...phase 4 heads, twin overhead cams...600 horsepower through the wheels, she’s meanness put to music...”

  16. #16
    Join Date
    Nov 2020
    Location
    Los Angeles
    Posts
    49
    My Cars
    01 540it
    It is DONE. I knew the dual exhaust conversion on these things was difficult, but wow, to say that is an understatement. There are many ways to do this, but having dual mufflers was important to me - simply adding a pipe with a tip was never an option. That said, I went with the OE M5 cans. Why? You can pick up a set for cheap and it gives the car the OEM+ feel. The only other option (for me) would have been Dinan, which for now is way too expensive. All together, this job was around 50-75 hours.

    - Trunk was stripped and sound deadening was applied (Matt 66)
    - Pipe welding was all done by my local profession exhaust shop
    - Slimbones rear lower diffuser

    Image from iOS (19).jpgImage from iOS (20).jpgImage from iOS (21).jpgImage from iOS (22).jpg
    95 M3 - Sold
    00 330ci - Sold
    04 M3 - Sold
    01 540it - Daily

  17. #17
    Join Date
    Feb 2014
    Location
    Alexandria, VA
    Posts
    8,664
    My Cars
    ‘01 540’00 528T’03 525T
    How’s it sound? Nice job! I’ve done it on a customer wagon, but never have the time to do it for myself.
    Set the controls for the heart of the sun

  18. #18
    Join Date
    Nov 2020
    Location
    Los Angeles
    Posts
    49
    My Cars
    01 540it
    It sounds very OEM. No drone, not too loud or anything. I'm not looking for a loud setup, but I would have loved for this to be about 10% louder. I guess I'll have to pick up some Dinan mufflers one day

    Quote Originally Posted by BimmrMeUpSnotty View Post
    How’s it sound? Nice job! I’ve done it on a customer wagon, but never have the time to do it for myself.
    95 M3 - Sold
    00 330ci - Sold
    04 M3 - Sold
    01 540it - Daily

  19. #19
    Join Date
    Feb 2014
    Location
    Alexandria, VA
    Posts
    8,664
    My Cars
    ‘01 540’00 528T’03 525T
    Nah man, leave the way it is. It looks like the car came from the factory the way it is. The wagon that I transplanted the M5 bits on, the guy went and got the M5 exhaust done after he picked the wagon up from our shop, I never got to see it since he picked it up from us. I was hoping he’d swing by.
    Set the controls for the heart of the sun

  20. #20
    Join Date
    Aug 2016
    Location
    Virginia,USA
    Posts
    2,971
    My Cars
    528i, 525iT, M5, x5 4.8
    Yes to Dinan!
    Attached Images Attached Images
    Current Garage Highlights
    2005 X5 4.8is Le Mans Met Blue
    2003 525iT TiSilver
    2002 M5 TiSilver
    1998 528i KASCHMIRBEIGE METALLIC (301) (Goldie)

    Former Garage Highlights
    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

  21. #21
    Join Date
    Nov 2020
    Location
    Los Angeles
    Posts
    49
    My Cars
    01 540it
    -Valve cover gaskets (FCP Euro) x2
    -Valve cover grommets (FCP Euro) x22
    -Camshaft solenoid front case cover gaskets (FCP Euro) x2
    -Timing chain tensioner (FCP Euro)
    -Powder coat valve covers x2
    -NGK Spark plugs (FCP Euro) x8
    -Oil change w/Castrol synthetic @ 138,950 miles

    Open.jpgVCs.jpgcomplete.jpg
    95 M3 - Sold
    00 330ci - Sold
    04 M3 - Sold
    01 540it - Daily

  22. #22
    Join Date
    Nov 2020
    Location
    Los Angeles
    Posts
    49
    My Cars
    01 540it
    -Front M5 brake calipers
    -New OEM brake pads
    -Turner Motorsports stainless ABS module flex lines
    -Custom ABS module heat shield
    -Brake fluid flush (whole system w/Super Dot 4)
    -Stoptech (cryo treated and cross drilled) rotors
    -New intake manifold vacuum lines (x4)

    Image from iOS (1).jpgImage from iOS (2).jpgImage from iOS (3).jpgImage from iOS.jpg
    Last edited by Arson8; 08-05-2022 at 04:58 PM.
    95 M3 - Sold
    00 330ci - Sold
    04 M3 - Sold
    01 540it - Daily

  23. #23
    Join Date
    Nov 2020
    Location
    Los Angeles
    Posts
    49
    My Cars
    01 540it
    Transmission service w/ZF fluid @ 140k miles
    New transmission filter and OEM gasket
    All new transmission bolts and fill/drain plugs and washers
    Differential flush @ 140k miles
    New fill and drain plugs and washers
    New set of aftermarket pork chops
    Used M5 engine pan
    IMG_3353.jpgIMG_3355.jpgIMG_3361.jpgIMG_3363.jpg
    95 M3 - Sold
    00 330ci - Sold
    04 M3 - Sold
    01 540it - Daily

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