Hello !
I recently acquired a 2002 525i Touring Sport package with 189,000 miles. It has a full Christmas tree of lights due to sitting for around 9 months but it spent most of its time in New Mexico and has never seen Michigan's horrible winter salt roads.
It pairs very nicely with my Wrx wagon that has had a complete STi conversion done to it with all the best oem parts I can import. I just realized I am now 2/3 on collecting the Top Gear Africa challenge cars and I am not so sure to be concerned about it or just to continue to embrace it.
The build thread on the STi Wagon can be found over on Nasioc
The goal for the E39 Touring is to have a nice summer cruiser that I can drive to shoot pictures of motorsport events and run to Costco. I have always wanted one since watching the BMW Films in my teenage years and finally found the right chassis.
Now if this happens to include an S62 with ZF8/DCT or LS3 with ZF8/DCT with fully functional AC , cruise and powered everything that would be even better. That however is a few years down the road as I have to collect parts to make the interior and exterior nice first. With my past projects OEM parts are almost always the best option and I will be sourcing a lot of them from FCP euro.
Like all people in their 30s I have the usual social media and such
Website
Youtube
The Good
- AC works amazing
- Engine is very quiet no Vanos noise or valvetrain noise
- No rust
- Drives quite well for having so many codes , these cars are proper tanks like my VW Touareg TDI
- The color is absolutely phenomenal and matches my other financial nightmare
- No Engine codes !
- Beautiful Sport M wheel
The Bad
- Smells a bit odd and needs a serious detail
- Headliner is sagging
- TCU Codes due to either low fluid or low battery
- ABS codes either from a bad sensor or transmission codes
- Brake code for either low fluid or pad sensor failure
- Glovebox won't open
I have already started ordering a bunch of parts from FCP Euro to get it back on the road and cruising for the Woodward dream cruise in August.
Service items coming up are
- Interior and Exterior detail
- ATF fluid top off to clear codes
- front and rear brake job
- Brake fluid flush
- Oil change with fresh 5w40 Liquimoly
- Differential fluid change
- Replace drivers side rear light that is showing as failed
- Pin up sagging headliner as a temporary fix , pull or source a replacement headliner during winter
- Replace all wiper blades
- Replace rear badging with new oem
Can't wait to see where you go with this thing. I've followed the build of your WRX on NASIOC pretty much from the start, and it is one of my faves.
Current Whips: 10 E90 ///M3 - 04 GMC Sierra CCSB - 19 VW Atlas
Past BMW's:
85 325 - 87 325is M-Tech 1 - 91 318is S50 swapped - 91 318i 'vert
97 M3/2 - 98 M3/4/5 (Alpine/Modena) - 98 M3/2 - 98 M3/4 (Dakar)
06 330xi - 09 335i
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
Hi,
Another one being made! excellent ! My usual question next, will you be looking to keep it looking all OEM as if BMW had indeed made an E39 M5 Touring? or will you do it with some choice styling and performance upgrades/enhancements?
Over the years, numerous M5 Tourings have been built, 98% of them perhaps all looking OEM and a few that have a classy modified look. Perhaps one of the very best project threads is this one which has just been done over the last few months or so by a owner who runs his own very well reputable BMW specialist garage. He's gone to the technical level that perhaps BMW would have done - i'll let his build thread explain! - https://forum.bmw5.co.uk/topic/14419...touring-build/
I may just have to convert my Touring .. in due course!
Cheers, Dennis!
As always, thank you Dennis, I have been looking for a writeup on a RHD M5 conversion for a while now to see if there is anything different than the LHD conversion, will have to read through all of that thread to see if anything is actually different in terms of the build process.
JN Garage, with the wagon being a 525 and not a 540 there will be some additional things you need to do, such as retrofit the entire front subframe and all the v8 stuff before you can plop an s62 into it. I am not 100% sure what is required but it will definitely be more work than starting off with a 540. The most common retrofit into a I6 car is an LS swap as you don't need to replace the subframe
I am also in the process of gathering parts for my m5 conversion, the timetable has been moved back until next summer because I got a late start on it this year. Good luck with the build, I am looking forward to big things, great color btw
Also, welcome to the forum
Here are some links to go through:
s62 into any e39(https://www.bimmerforums.com/forum/s...39-525-530-540) *must read, really well done write up*
e39 427 build video (https://www.youtube.com/watch?v=C6TnC39j8Gk)
e39 427 exhaust(https://www.youtube.com/watch?v=V8l_8rp-fek)
Current:
2000 RHD Euro Sport Slicktop 540it Glacier Green/Black
2009 LHD e92 335i Sport Black/Black
Former:
1997 5sp locker 4Runner Green/Beige
1991 Buick Park Avenue Gold/Beige
That build thread is phenomenal so far I have bookmarked it.
I am not 100% decided on powertrain as the goal is to have a very nice summer cruiser that I can enjoy in any weather. Being a Subaru Oem purist it only makes sense to source the best oem BMW parts I can even if it costs more and takes longer. But being in Detroit I have access to an insane amount of LSX shops and endless GM performance parts at bargain prices so its something to consider even as much as I love the S62. If the S62 route is chosen I will need a donor car to make it work properly.
The only things I would really consider changing would be the interior seats ideally sourcing a more modern BMW option seat or something like a Recaro Sportster CS.
Right now the goal is to get the 525i powertrain running smoothly for the Woodward Dream cruise so I can just cruise around in it
I had that first hyperlink bookmarked since like 2018 and have read it like ten times its really good.
Its going to take a long time as my Wrx to STi Wagon conversion is only like 90% finished while having owned that car for nearly 9 years. If I were to even estimate a timeline it would be 3-6 years for complete Exterior , Interior and Powertrain conversion. But it will only be done if everything functions at an oem level like HVAC , Cruise and such.
I am not a very good fabricator and an average mechanic but I know some excellent people who work for Tier 1 / OEM automotive companies in the Detroit area so I will be paying them for their services in the future.
Hopefully by the end of the month I have it on the road and properly detailed so I can get some nice pictures to document the start of the process.
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
This is also a good read - https://www.m5board.com/threads/jeds...thread.203073/
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
Previous owner said he drove it to Wisconsin , Chicago and Ohio frequently which makes sense now as this thing is about as immaculate as a 20 year old wagon can be considering its 190,000 miles. I am hoping that the TCU codes are all just from sitting for 9 months , some stupid abs sensor or a little low on fluid.
I have been reading BMW diy articles for the last week now and its amazing the amount of detailed writeups there are on 3rd party websites such as FCP , ECS , Pelican and independent shops. The forums are still very much alive compared to the Subaru world.
Crawled under the car today and its missing a few underbody panels here and there but nothing extreme. Quick jacks are amazing and I realized just how much longer the E39 is compared to my Wrx but it fits nicely into the service side of my garage. I also hung a few led lights as well as cleaned the entire garage from last weekends Subaru nightmare of leaking fluids ( Not my car a friends , my Subaru nightmare somehow does not leak)
There appears to be a minor oil pan leak going on but its nothing compared to some of the Subaru engines I have had , It honestly looks like a 100,000 mile Subaru engine getting its first timing service. The entire chassis is in amazing shape for a nearly 190,000 mile chassis. The use of aluminum , copious shielding and galvanized steel is wonderful. I can basically eat off the heat shields after I wipe them down with some simple green.
There one of the outer tie rod boots has a tear in it and a brake sensor is zip tied to the shock body but nothing really extreme. The engine starts right up , idles fantastic and revs freely. AC kicks on and operates as you would expect in an oem fashion. The cooling system was full of coolant and did not show any signs of leaking from the 30 minute drive over to my house two weeks ago in the pouring rain with the AC blasting. It can definitely use a brake job and some simple green cleaning on the parts. Coming from dealing with rusty midwest Subaru's this is going to be a delight to work on.
I got an additional order of BMW specific sockets and tools that will assist me as I am foreign to those fancy torx sockets or oil housing wrenches.
Tasks for this next week are as follows
Top off ATF with ZF oem
Brake job
brake fluid flush
Diagnose rear bulb warning light , replace failed bulb
Oil change with Liquimoly 5w40
Replaced all wipers with new Bosch wipers
Replace rear emblem with a new oem emblem
Tasks for the near future
Replace axleback exhaust with a custom Vibrant muffler and tip to replicate the factory exhaust
Take it to my local detail shop for some love
Clean up interior and start shopping for leather restoration services in the area
Install bluetooth adapter from GROM (Bluebus is backordered till October at best)
Upgrade audio with a kit from Bavaudio or Crutchfield
Drive it to work in September / October for fun
All goes well it will be on the road next weekend getting miles put on it going to Costco , I have a Michigan SOS appointment next Tuesday to register it as well.
Here are some pictures
Cars like this simply don't exist in Michigan this one is amazing, If anyone has suggestions for potential Oem+ mods I would love to hear them as I want to make this as nice of a cruiser as I can.
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
Hey JN Garage, you might want to take a look at my DIY thread for just such a conversion: https://www.bimmerforums.com/forum/s...39-525-530-540. For a facelift e39, it's pretty well covered. One thing I would be concerned with is if your car has a low or high cluster. If it's a low cluster, you'll need to do a good bit of wiring to convert it to a high cluster as well as some coding. This is required if you want to run the M5 cluster. If not, you can keep your 525 cluster, but where's the fun in that? Also, PM me if you need a M5 cluster or if you find one and need mileage correction/coding.
I've either done or helped on a few of these conversions in the past, so if you have any questions, just let me know. Also check out Speed Academy on YouTube as they just recently did a M5T build and I helped them get through a lot of their build. They talk about a lot of the "gotchas" you will likely run into and how they solved them.
- - - Updated - - -
It also goes without saying you'll want to do all the standard e39 touring maintenance stuff, such as subframe bushings and rear hatch struts and such. It looks like you're on the original suspension in the rear, so I'm sure it's about shot. I recommend going with the M5 subframe bushings in the front and touring in the rear. This will allow you to use the M5 subframe connectors on the wagon, which won't work otherwise. If you need to rent the tool to do the subframe bushings, let me know as I have one to rent.
-Paul
2003 "M5" - Full M5 conversion, AMG C63S 6 piston front calipers, Porsche Panamera 4 piston rear calipers, GC Coilovers, Eibach ARBs, UUC Evo3/DSSR, Borla Exhaust w/Muffler Delete, BMW NBT with Carplay/Android Auto, Bi-Xenons, e38 Style 37 M-Pars, e60 Hubs 530i 6-speed swap build thread2005 Range Rover 4.6is (M62TU Powered) - 4.6is Engine Swap from X5, BMW NBT with Carplay/Android Auto
2006 Porsche Cayman S - Soul Performance Competition Headers and Exhaust, H&R Coilovers, 718 Boxster Spyder wheels, Rennline 35mm rear spacers
I have had your diy bookmarked since like 2017 in anticipation for my second project car , all upgrades are on hold until I sort it out mechanically as its in need of some love. I will definitely be renting that tool in the future and getting in touch with you for the M5 dashboard.
Right now I spent the weekend doing fluid changes on it and diagnosing a misbehaving a DRS 3 solenoid code that is triggering brake and ABS codes as well. I am thinking that the car has sat for 9 months so possibly the solenoid is clogged up or was subjected to low voltage. Either way worst case I will have to drop the transmission pan then replace the solenoid that is faulty.
Just checked my pictures and unfortunately I have the low cluster lacking the two knobs , Luckily I have a friend who is an electrical engineer who specializes in canbus so he loves this kind of stuff.
Last edited by JN Garage; 07-18-2021 at 07:47 PM.
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
So during the weekend I did a fresh 5w40 Liquimoly oil change and the M54 got even more quiet. Its honestly amazing how smooth these engines are I love them. I also sorted out a bunch of little things such as light bulbs being out and other little errors on the car. I also confirmed that all my wheel speed sensors are working properly. INPA software truly is amazing with what it can do. I then drove the Subaru out for some fresh E85 and to cruise around Woodward avenue for a bit.
Still troubleshooting the EDS 3 error code which keeps popping up when applying load in 3rd gear or when applying load with the car in drive.
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
Nice set of wagons! I too came from Subie-land, with an 08 Leggy GT manual.
I recommend driving at 530 with a manual as some driving homework before deciding on what to do about power. Half a liter and a stick shift make a huge difference in how the car feels to drive. I currently have one of each (525iTA and 530i 5spd), and plan to find an M54b30 for my wagon after the 530 goes off to live with my parents. Not sure if you've driven any NA I6 manual BMWs before, but the smooth linear power and throttle response make for a sublime driving experience. From there you could always go forced induction and/or cams if you're craving more power. Sticking with the I6 configuration saves you the hassle of a subframe swap and allows you to keep that sweet rack and pinion steering.
Check out Stuck's build thread where he put an M54b30 from a ZHP E46 into his 525i, then supercharges it. It's one of my all time favorites.
https://www.bimmerforums.com/forum/s...6SPD-Build-Log
ETA: one of the best chassis upgrades you can make is an M5 rear sway bar, with bushings and brackets. You'll go from 13.5 mm to 16 and definitely notice an improvement. Eibach is another option if you want to go even stiffer but they're NLA new so harder to find.
Last edited by chuckesteeze; 07-19-2021 at 02:27 PM.
I had a 2006 Legacy GT 5AT car as well ! , I kinda miss that car sometimes but it leaked far more oil than my BMW does.
I have really given the whole swap thing a lot of thought and an M54B30 is definitely on the list. This car is mainly going to be a cruiser so if anything I would install a ZF8 behind it instead of the ZF5hp19 it has now just to modernize it with an HTG controller. But since that controller is a few years out I am going to just wait and see.
I will go read that build thread as it sounds really good.
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
Gearbox update , I had a great idea during lunch to set it into diagnostic mode then watch the solenoids work. I did that a few times and eventually got it running into all the gears including 3rd again ! So now we have to see if this sticks , I am hoping due to sitting for 9 months it was just clogged up. Now I sat in it for 15-20 minutes just going into each gear back and forth. Time to register it tomorrow morning then see if that fix worked !
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
That EDS 3 code is still lurking around , Its looking like I might have to do a trans flush and replace the solenoid while I am at it.
Drove out to costco for some fresh 93 octane and a hotdog
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
Chuck this thread got me down the rabbit hole of M54B30 turbo engines and I think that is the ticket. I love how smooth the M5X engine is and I know a local fabricator that makes a very nice turbo kit that does not sacrifice any oem functions. Obviously there will be thermal considerations to worry about but that is pretty easily fixed.
I think its a great change from the standard S62 touring's while also being far easier to integrate than an LS3 or S62. It should be able to make 400-500hp reliably on E85 which is at literally every gas station in my area.
This would keep the car all oem BMW and it would have a very oem+ feel to it.
The plan would be the following powertrain
M54B30 / M52B28
E85
M50 intake manifold kit
Low mount Borgwarner S257 turbo
ZF8hp70 or ZF8HP75 from a modern B58 powered car
HTG tuning controller
Custom driveshaft
M5 or 540i differential with an LSD
Last edited by JN Garage; 07-22-2021 at 03:17 PM.
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
Glad I could be the devil on your shoulder! Did you find any good turbo threads to dive into? I've never really given turbos much consideration for my E39 - I have a Fiesta ST to scratch that itch and want to try something different. What led you down that path instead of a blower?
I have a few local drift guys with E46s that have been extremely reliable on M52/M54 turbo engines with a manifold that keeps all the factory features along with having good heat shielding. They are making 400-500whp reliably on the stock MS43 ecu , Maxxecu and Link G4 ecus. So I am very lucky to have locals who are very good at it. Seems Legit Garage also has a lot of experience with the HTG tuning TCU controller as well. My friend has a purple RX8 with a 2JZ and BMW DCT 7 speed that is running the same controller as well its going to be absolutely terrifying.
The honest answer is I really really love turbo engines and a turbo inline 6 would be peak BMW in my opinion.
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
Drove it around for an hour with a good old Italian tune up and for 20 miles the transmission code stayed away so that is a great step. Still have a pressure sensor code 81 to sort out but its probably the ABS controller that is just dead.
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
Electrical gremlins return
Battery voltage on startup was only 11.30 this morning when I went to run errands causing all sorts of fun codes.
Going to hook it up to a tender and see how it goes tonight
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
I don't think you've mentioned it yet but based on the pictures it looks like your touring doesn't have a sunroof? If true, that would make it a very rare E39 touring spec for North America.
1999 540iAT Glacier Green / Black
2003 525iT/5 Oxford Green II / Beige
2011 328i Conv. Platinum Bronze
It does not which is one of the reasons I bought it
The battle continues with tcu codes. No engine codes at all which is odd.
The car drove perfect for an hour earlier this week but then overnight everything returned which is very odd
Codes are as follows
Body
141 Aux Fan
199 Tank level sensor
Transmission codes
49 Gear Monitoring
34 Transmission temperature sensor (Intermittent)
Replaced battery and it idles at 13.8v compared to before at 11.3 with the AGM battery
Still threw some codes on a test drive I think the ATF cooler is clogged now ATF temperatures over 210-220f or the fluid is toast.
Electrical woes continue , Going to step away from it until the weekend.
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
Get that battery load tested. There is either a drain overnight, or it is no longer any good. AGM or not, if it fails a load test, it has to go. / edit - sorry, did not realize battery was replaced. Check draw after he goes to sleep. - does the trans indicator light turn off after 15 min?
Last edited by CPHES; 07-28-2021 at 11:31 PM.
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