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AZBMW Forums › Model Specific Discussion › 5-8 Series › e39 540i project (photos) update (5-26)
e39 540i project (photos) update (5-26)
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giantkeeper
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PostPosted: Wed Mar 13, 2013 4:48 am
Post subject: Re: e39 540i project (photos) update (3-12)

Good work Jr, thats what I call taking pride in ownership!

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sterling
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PostPosted: Wed Mar 13, 2013 10:44 am
Post subject: Re: e39 540i project (photos) update (3-12)

Bravo! Thanks for saving an awesome car!
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ccc13
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PostPosted: Wed Mar 13, 2013 11:24 am
Post subject: Re: e39 540i project (photos) update (3-12)

Thank you for doing the job I didn't have time for!

Well done.
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ambition
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PostPosted: Wed Mar 13, 2013 12:10 pm
Post subject: Re: e39 540i project (photos) update (3-12)

Is it just me or does the stock 540i exhaust system look really restrictive?

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wkohler
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PostPosted: Wed Mar 13, 2013 12:29 pm
Post subject: Re: e39 540i project (photos) update (3-12)

Can you see inside the pipes?

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rmehrIV
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PostPosted: Tue Mar 19, 2013 9:30 pm
Post subject: Re: e39 540i project (photos) update (3-12)

Well I am sorry to say but, "She is under the knife AGAIN..." Finally, once I was able to drive the car, I went down to the DMV to get tags and a plate. I came to find out that I needed run the car through emission. Ever since I started the car the CEL light has been on. Once I got the temporary tags I drove it down the Checker to have them scan it only to find out that they weren't getting a connection from the OBDII port. I was a little dumb founded so I looked up on the internet and talked to a few people who believed that the ecu needed a few drive cycles in order to finish running through all it tests. After driving it all weekend the CEL light and the battery light was still on and when I went back to Checker they still got no connection. This time it sad something about the DLC port not having connection. When I got home I double checked all the fuses come to find out that diagnostic plug fuse was blown and the DLC cap wasn't screwed down all the way. After starting the car the battery light went away, the car also became a lot more responsive, and pulled a lot harder. But the CEL light was still on. So I took it to Alex Vaughn at Vaughan Motorworks to have him scan it which read that all four knock sensors are faulty. So once I got home I began tearing apart the engine again. Hopefully I can get it started running again tomorrow, get it through emission by end of this week and send it to paint next week!
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ccc13
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PostPosted: Tue Mar 19, 2013 9:43 pm
Post subject: Re: e39 540i project (photos) update (3-19)

Ugh, sorry to hear it's a pain in the arse issue instead of a glitch. Hopefully this gets it sorted.
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bastarde38
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PostPosted: Tue Mar 19, 2013 10:20 pm
Post subject: Re: e39 540i project (photos) update (3-19)

be careful when installing those knock sensors. they are very sensitive to being torqued down properly. find the spec and use a good torque wrench (not something from HF or vato-zone)

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PostPosted: Tue Apr 02, 2013 8:12 pm
Post subject: Re: e39 540i project (photos) update (3-19)

Took a little bit longer then expected to fix the knock sensor problem because I had to wait a few days for the part to come in. When the part finally arrived had it back up and running within an hour or two. Along the way I also ran into a few more issues such as throttle sticking open, misfire code popping up but got that all figured out. After getting the computer reset and drove it for a couple of miles I took it through emissions and passed! After getting tags I took it to the freeway did a couple WOT runs and the car pulls like a mother f***er! Anyways, now that the car functions properly there are still a few more things I am going to be doing.
List:
1.) Paint the panels that need a touch up. (May send it to the body shop later this week or early next week)





2.) Detail the rest of the car inside and out.


3.) Replace the brake pads.
4.) Get the a passenger fog light.
5.) Get a hood underliner.
6.) Fix the rear window regulators.
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rmehrIV
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PostPosted: Fri May 24, 2013 11:17 pm
Post subject: Re: e39 540i project (photos) update (4-2)

Well it has been awhile since my last update but during that time I seemed to have got a lot of things done to the car. I also took the car on 500 mile British/Euro car rally. It did really well with no problems! Here are some pictures of me driving into Whiskey Row in Prescott and Jerome.



The day before the rally wasn't so much fun since I spent all day Friday working on it changing brake pads, fixing oil leaks, flushing the power steering system, spark plugs, etc. It was also a pain in my a** trying the get the rims off the rotors since they were stuck together with surface rust. Once I got off all the rims and finally changed brake pads I decided to take a wire wheel to the rotors to remove the surface rust and clean the rims. After learning from my mistake the first time I applied a little bit of grease so hopefully in the future it won't happen again!




The week after the rally drive I finally got around to ordering new rear window regulators and fix the a/c since the compressor went out. It was a pretty straight forward process replacing window regulators and wasn't to difficult.

This is the broken regulator; the bracket that is suppose hold the window and connect to the cable that pulls the window up and down.



I was trying to be careful with trying to pull the tape that held up the window so they would not leave any residue but it did... Since I didn't feel like getting the windows re-tinted I took sometime to find what would take off the residue and turns out that wd-40 works the best!
Before:
After:

New Packages that arrived that day!
They finally stay up on their own without any tape!

Now that the interior is finally coming together I started to clear the floor mats since they were in terrible condition. So I took them out vacuumed them really well. Next step was I used some Simple Green mixed with water and sprayed that all over the floor mats but made sure that I sprayed an excessive amount over the areas that were really stained. After letting it sit in for 5 mins or more on each mat I took a brush and started scrubbing away. The final step was washing them off with a hose and some sh***y attachment until all suds were gone (if you have a power washer it will make the process a lot faster!). I seemed the have gotten all the stains out of the floor mats.
Before:

After: (The drive-side floor mat was still wet making it look darker)

Items I used to clean the mats! haha

I recently took it to get painted and get some dents fixed. I still need to detail the original paint to match the new paint, and inside but I am very pleased with the way that it looks! Sorry for shit pictures at the paint shop I forgot my camera and had to use an Iphone.










I also took apart the hydro-locked engine out of curiosity to see what actually failed and will post more pictures sometime this weekend. Later this week I will post more pictures after I finish detailing it! Thanks for looking!


Last edited by rmehrIV on Fri May 24, 2013 11:22 pm; edited 1 time in total
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wkohler
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PostPosted: Fri May 24, 2013 11:20 pm
Post subject: Re: e39 540i project (photos) update (5-24)

Wow. What a transformation. Looks great, though I think they painted part of your license plate. Wink

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10/80 E12 M535i | 12/82 E28 533i | 4/83 E28 533i | 3/85 E23 745i | 6/85 E28 M535i | 7/86 E28 535is | 5/94 E34 525iT
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ccc13
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PostPosted: Sat May 25, 2013 2:41 am
Post subject: Re: e39 540i project (photos) update (5-24)

I'm look forward to each update to see the car get better and better thanks to your work. Looks awesome!

I'm also very interested in details of the engine failure, since I never had the time to look at it.
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rmehrIV
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PostPosted: Sun May 26, 2013 10:03 pm
Post subject: Re: e39 540i project (photos) update (5-24)

Here is the tear down of the hydro-locked engine!





Once I removed the headers from the from block I saw that there was a hole on top of the one I took a picture before. In the corner of the top hole you can see what was the broken rod.

Another couple of holes in the oil sump pan.



If you look at the bottom right of the crank you will notice that the rod from cylinder 8 broke.




Here is the culprit to why the engine hydro-locked!!

The crank looks pretty cool!


Small Photo Shoot:







Finished Project and All Detailed:













Last edited by rmehrIV on Mon Jul 22, 2013 11:11 pm; edited 1 time in total
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ccc13
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PostPosted: Mon May 27, 2013 10:52 am
Post subject: Re: e39 540i project (photos) update (5-26)

Jeez.
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senorcarey
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PostPosted: Mon May 27, 2013 4:48 pm
Post subject: Re: e39 540i project (photos) update (5-26)

How well do you feel that M62 powers your E39? I've got an M60 that I have sitting in the garage just aching for something to go into, yet for the work, I'm not sure if I can bring myself to use it.

Nice work getting the car rolling, by the way. The car has turned out pretty nice.
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