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Chapter 2: Maintenance Round 1
Mileage: 102,917km
Service Booking Date: 23 Jun 2025
After weeks of research, ordering parts, waiting for delivery, waiting for labour quotes, ordering more parts, finalising the initial job scope, my M5 finally went to Garage808 for it's first big service. The initial goal was just to fix the most obvious stuff so that it will pass RWC, but of course being me, the scope inevitably grew.
A big consideration for some of the work is the lack of availability of parts. These days when I email the dealer for quotes, I also have to ask how many are left in Germany to get a sense of how close to being NLA they are. There are some alarming surprises. If parts are still available, it’s also a matter of when will the price double as supply begins to dwindle. Needless to say I am probably covering what would normally take me 3 years in about 3 months. Anyway, here we go:
The M5 was at
Garage808 for a total of 12 working days which was much longer than expected, but I appreciated that they were being careful with an old and special car, and it was a lot of work.
A few parts, nicely organised per job, into boxes or bags with RealOEM printouts and part numbers highlighted to ensure no confusion.
Job 1: Inspection 2 Service
We start with a full service that includes the following:
- Oil (BMW 10W60) & Oil Filter
- Cabin Air Filters
- Air Filters
- Fuel Filter
- Spark Plugs
Note: Gearbox and Differential Fluid to be done at the next booking due to more logical pairing with other work that is scheduled.
Job 2: Replace Oil Level Sensor and Inspect Sump gaskets for leaks
Hella Oil Level sensors are unfortunately no longer available, so that means this is a dealer-only option, so may as well get it done now before the pricing gets worse (you'll notice a lot of this principle being applied in this project). There was no immediate evidence that either the upper or lower sump gaskets were leaking, but we still need to do more cleaning on the front of the engine to be sure.
Job 3: Replace all brake Hoses with Turner Motorsports braided hoses and flush brake fluid, including clutch line.
The brake lines in the engine bay are a known fire risk, so when I was in the US I picked up a permanent solution for this. Unfortunately it turns out that when you replace the brake lines at the ABS module and introduce air into that part of the system, it’s a giant pain to bleed the brakes properly. Ryan from E39source confirmed this to the the case every time he replaces these lines. So despite Colin’s best efforts of bleeding the system twice, I can feel there is still air in the system. No worries, the car is going back in 2 weeks time and I’ll give them the extra feedback.
These ones that connect to the ABS module in the engine bay are the fire risk, but the kit replaces all the brake lines.
Old and dirty
Cleaned up
Brake Fluid Reservoir properly cleaned out
Job 4: Replace Rear Anti-Roll Bar Brackets
A very common issue is for the rear anti-roll bar brackets to break off. The left side had done this, so I replaced both, including mounting hardware. Below you can see the photos of the left bracket that had broken off. BeastPower in the US make a permanent fix for this, but at some 800.00 USD, the OEM ones will do for now.
Old broken bracket
New OEM brackets installed
Job 5: Replace Left Rear Door Lock Actuator
I noticed that the left-rear door lock actuator on this door was getting rather lethargic, and not wanting it to fail in the locked position I figured it was best to get in front of this issue. As you can see from the pics below, the vapour barrier had also started to separate from the door which is completely normal for an E39 M5 at this age. Colin apparently took 2 hours to remove all teh old Butyl and beuatifully resealed it. At least the vapour barrier itself looks to be in good condition, which is not always the case!
Vapour Barrier separating from the door
Vapour barrier removed and old butyl being removed
Vapour barrier still in good condition
Fresh Butyl Applied
Vapour Barrier properly resealed
Job 6: Valve Cover Gaskets and Cam Position Sensors
The left bank valve cover showed signs of slight leaking and at this age and mileage, these need doing anyway so both got added to the job scope. At the same time, I had an error code for Bank 2 Exhaust Cam Sensor. Knowing that these sensors are quite common to fail, I decided the most prudent thing to keep this S62 running nicely was to do all four.
Colin was kind enough to clean the valve covers, something that I did not request but he couldn’t not do it, and I really love that!
Job 7: New Engine Mounts
These had not outright failed, but I've owned enough BMWs of this era to know the feel of when they are starting wear out. It mostly affects the ability to shift between gears smoothly as well as there being excess movement in the drivetrain when coming on and off power. At this age and mileage, they need doing. Gearbox mounts to be done in the next iteration of maintenance.
New engine mounts fitted