E39 540i Manual project

Benji

Well-known member
Life being what it is and me being who I am, I have somehow ended up with another project car through no fault of my own. Of course :rolleyes: The sheer quantity of broken BMWs in the yard are getting harder and harder to explain to my significant other.

I found a clean enough E39 540i for a decent enough price during some idle browsing on Facebook Marketplace. Interest was quickly piqued by the 3 pedals visible in one of the pics! I naively thought that having a look at the car wouldn't hurt. I test drove the car and found it to be in surprisingly good condition and found myself driving the car home after the seller accepted my low ball offer, wondering what I've just gotten myself into and where I am going to find parking for the car. First world problems if ever there were any.

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I am really impressed with the refinement and feeling of invincibility this car gives, notwithstanding the tired suspension etc... As I brought it home, a relatively well looked after 200k car in old man spec - my favorite! Car seemed to have been recently neglected which as you know, is the best kind of neglect. Issues include but are not limited to - difficulty in selecting gears, occasional misfire, death wobble, missing front spoiler, and the whole front had been poorly repainted but I could not find any signs of an accident. It seems the fan clutch failed which led to a fan explosion and much carnage. Said carnage was very poorly repaired. First order of business then was to sort that out and in typical fashion, get carried away and spend too much money while at it. Because that is the correct way of doing things.

An example of the carnage that was fixed with some silicone and an ice cream tub to seal a hole in the MAF?? How was this car even running?
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Before:
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After:
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Yes, I did take it too far, but it is good to be thorough. At least, that's what she said.

I procured a OEM spoiler at a rather heinous price, even after the ABM discount. Will paint once the bank account recovers.
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Now to do some general maintenance and sort out that misfiring which I suspected was due to leaking valve covers.

If only my wife was this dirty:
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Looks like the previous owner kept the spark plug fluid topped up (y) That was about 250ml of oil removed from just the one head :rolleyes: Again, how was this car even running? I dare say we found the cause of the misfire... Otherwise there is very little varnish inside the motor and no broken timing chain guides from what I can see from the top of the motor :cool: now we can all breathe a collective sigh of relief...or maybe we should hold that breath for when I open up the sump...🧐
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Seems I got carried away again. Figured while I was in there, I may as well do the valley pan gaskets and those silly coolant cross over pipes with new CCV and inlet manifold gaskets etc. Pity the wallet.

Anyway, it is all forgiven with a gratuitous pic of that rear end. It really is a good looking rear, no?
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KPM3_30

Moderator
Staff member
Excellent thread, enjoy the writing. Oh, and that rear looks really good.. E39 is a special looking car, congrats.
 

gavsadler

///Member
Looking forward to the updates on this thread.

I think what you saved on the low-ball purchase price may be offset by a diamond or two at Browns in the coming months.

#compensation lol
 

migz_330i_

New member
Keep us updated in this thread. Really enjoy the process:) also I never seen a 540i with that rear bumper it's really pretty to look at
 

Benji

Well-known member
Thank you for positive comments, slowly working putting everything back together, should have it running within a week provided I dont get lost down another rabbit hole of parts...
 

Benji

Well-known member
Keep us updated in this thread. Really enjoy the process:) also I never seen a 540i with that rear bumper it's really pretty to look at
Yeah its the aero package bumpers that came on all the early 540 manuals. I think it is a much more unique look compared to the later M-sport/M5 bumpers
 

Meep

Active member
Yeah its the aero package bumpers that came on all the early 540 manuals. I think it is a much more unique look compared to the later M-sport/M5 bumpers
How did you even source the front spoiler? I saw it was plastic but still, as far as I know they are very rare. But nice thread and thanks for saving this legend.
 

Benji

Well-known member
How did you even source the front spoiler? I saw it was plastic but still, as far as I know they are very rare. But nice thread and thanks for saving this legend.
I bought it thru BMW, I think there were 4 left in Germany when I bought mine. The hardest part was finding the part number :ROFLMAO:
 

Spanky

Well-known member
Lovely job, Benji. Keep it up!

You're like SA's Sreten. Both in car renovation knowhow and communication style.
 

Benji

Well-known member
Lovely job, Benji. Keep it up!

You're like SA's Sreten. Both in car renovation knowhow and communication style.
Getting some M539 Restorations vibes here looking forward to more updates! :)
Some high praise here guys, thank you 🙏 Streten is my role model when it comes to cars and his shows have been an inspiration for me to be better
 

Benji

Well-known member
Finally got the car running after finding myself a little further in the bowels of the engine than intended.

Decided the water pump was just too exposed at this point to leave it alone, so in went a OE Saleri pump. Glad I did this as the old pump bearings didnt feel too good.
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And all back together
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Found some very squashed fuel lines from a misguided offroad excursion. Again, how was this car running?
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Pipes replaced, filters changed and car started up beautifully! Much to my dismay, the misfire is still there! 😖 😖 so I've ordered a INPA cable and will do a diagnostic, its probably an ignition coil or 2 as mine look like the originals from factory. Still need to replace the thermostat, awaiting delivery from BMW on a 95C thermo which opens 10C earlier than the stock one.

Much to my utter surprise, the only oil leaks from this car was from a powersteering line gasket and the oil level sensor. Got the PS line sorted, will do the oil level O-ring when I open up the sump. It feels weird to have such an easy fix to oil leaks on a 24 year old BMW. Touch wood maybe?
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Next on the list is to fix the sloppy gear selection, had a quick look, there is so much play in all the bushes and linkages under there, will order parts this week, should be a relatively easy fix - famous last words.

Oh, does anyone know where this bracket goes? I somehow have it left over...Im sure it goes on the passenger side of the engine to support the wiring loom, but cant for the life of me figure out where. Its making me feel quite stupid...
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Benji

Well-known member
So for those who are sadistically following my escapades with this car; you can sigh your breath of relief. No plastic bits in the oil sump! This is good news indeed
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And there it is, a timing chain guide, resplendent in its intended position on the tensioner, not lounging about in the sump. Very good. Also not too much varnish, no sludge in the sump and no signs of previous entry - i.e, no gasket sealer on the sump gasket. These are all good things
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To my surprise, the oil filter had been changed after 29.12.2021...so the car has done about 500km on this oil (y) no funny business in the oil filter either.

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Shiny sump ready to go back in, obligatory new gaskets/seals.
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Time for some diagnostics, luckily I have a passing understanding of German. I swapped the ignition coil from cylinder 4 to cylinder 3, looks like my non-smooth-running cylinder followed the coil, so we have our culprit. Some more parts to order, hoping my tax return clears soon :rolleyes:

Before:
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After swapping coil:
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I suspect I have a vacuum leak on cyl 3&4 since they share a gasket and both have high readings...also I do hear a bit of a hissing noise from that side of the inlet manifold. Anyone have a smoke machine they recommend to test for vacuum leaks?

Next lady for a shave is the engine always dying when its started from warm. Generally at a fuel station, starts up, runs for 2sec, then dies. You then need to ref it like you is from Benoni to keep it running. Very embarrassing for such a distinguished machine. Pulled codes, I am suspecting camshaft position sensor, however, it does not throw an error when the engine is warm (note engine temp on diagnostic). it does have very frequent Lambda errors, not sure if I should be worried about this? Car only has pre-cat sensors and has been decatted somewhere in its life
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Benji

Well-known member
Small update. I procured some ignition coils which fixed the high smoothness value on cyl 3. Result! Took the car for a drive, it still misfires 😩 checked on INPA, cyl 1 was running very rough, tried swapping coils, spark plugs but misfire stayed on 1. Swapped injectors over and the misfire moved with the injector. Stole an injector from the E34 and it seems to be running good...for now :rolleyes: Why the injector would choose this moment to die after I had fixed the ignition coil is quite baffling
 

Benji

Well-known member
So I found some glitter in my oil :confused: M62 life FTW. FML. 🤦‍♂️ So timing chain kit is ordered with all the "while you're in there" bits ordered. Except for the bits I've forgotten to order, obviously.

In the meanwhile, I've found a set of pre-facelift clear indicator rear lights, OEM xenons and one front light with the clear indicator...the search continues 🧐 Also a very rare set of Style 32s in 18" are on the car, not entirely convinced at this point. Will have to get the car running and see what it looks like out in the wild and with the spoilers all present and correct. I chose these wheels are they are an "OEM+" style upgrade

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Ooooh, how good does it look when dropped?? The wheel to tyre clearance is about as tight as a fleas arse. But clearance is clearance...
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