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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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rmehrIV
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PostPosted: Fri Jan 11, 2013 2:13 am
Post subject: e39 540i project (photos) update (5-26)

Some of you may recognize this car and that is because a few months ago I had bought this car for a fellow member named Craig (ccc13). I had originally bought the car with the intentions of swapping the transmission and a m62 into my e24. Though, I have changed my mind and decided that I would fix the car and drive it around during the time I finish my e24. I also felt that it would be a good learning experience on removing and transplanting a motor.
Anyways there are some little things that are wrong with the car and here a check list. Such as:
- The hydrolocked engine M62 engine.
- Hood still has the dents from an exploding fan clutch.
- Front bumper has chips and cracks.
- The passenger's side foglight is broken.
- Rear bumper has some clear coat fading.
- The front brake pads may need to be replaced.
- Rear window regulators aren't working.
First Day Home: (washed it and stored it)


I had stored the car for a few months while I gathered up some parts and got my e24 running. During that time I was able to find a motor.

When I bought the motor the left valve cover was broken and so was the sprocket. So I took to my mechanic to have him check the motor and do some work.
After replacing the sprocket and putting new valve cover gaskets the motor just needs to be cleaned a little bit more before I put it in the car.

I finally pulled car out of storage the other day! Gave it a quick wash a went to work starting to pull out the hydrolocked motor.

Wire-harness all taken off and labeled.

Other parts, hoses, etc taken off.


Organizing all the hardware.

After two afternoons I managed to get the majority of the accessories and wires off. Only have a few more bolts to take off and it should be out by tomorrow!

If anyone has any tips or hints on taking out/putting in the motor I would appreciate it a lot!

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Last edited by rmehrIV on Sun May 26, 2013 10:04 pm; edited 7 times in total
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senorcarey
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PostPosted: Fri Jan 11, 2013 7:11 am
Post subject: Re: e39 540i project (photos)

When I pulled mine out of an E34, the engine was much easier to pull sans exhaust manifolds. I believe the E39 frame rails are wider, though.

If you need an extra hand, PM me, as it can be a pain to do on your own.
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giantkeeper
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PostPosted: Fri Jan 11, 2013 7:27 am
Post subject: Re: e39 540i project (photos)

Take the hood off Ray Very Happy

Keep the transmission attached to the engine when you pull it out. It's far easier to disconnect the drive shaft and shift linkage in my experience than it is to remove the bell housing in the car. Plus if you need to change out the clutch it's all right there.

And thanks for sharing! Technically you are the first person to post in the 5 series section!!!

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ccc13
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PostPosted: Fri Jan 11, 2013 8:43 am
Post subject: Re: e39 540i project (photos)

Sorry for leaving such a mess, but I'm glad to see you're making progress on the project!
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wkohler
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PostPosted: Sat Jan 12, 2013 2:10 am
Post subject: Re: e39 540i project (photos)

giantkeeper wrote:
Take the hood off Ray Very Happy

No need to take the hood off. You can disconnect the struts and put it vertically.

Thanks for showing the progress.

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7/75 E12 530i | 7/80 E12 M535i | 2/85 E28 Alpina B7 Turbo | 3/85 E28 528i | 2/87 E28 M535i | 8/94 E34 525iT
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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SpikeX5
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PostPosted: Sat Jan 12, 2013 3:53 pm
Post subject: Re: e39 540i project (photos)

good call on the tennis balls on the work chair

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rmehrIV
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PostPosted: Sat Jan 12, 2013 10:06 pm
Post subject: Re: e39 540i project (photos)

Well unfortunately I had ran out of time on Friday to take out the engine and today I had work. But I will for sure have it out by tomorrow.
Here are some pictures of engine's damage:
There is still some water in the intake manifold.
Hole in oil pan.
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ccc13
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PostPosted: Sun Jan 13, 2013 12:13 am
Post subject: Re: e39 540i project (photos)

Ouch, I was going to ask if there was still water in the manifold.

If/when you tear it apart to see what sort of twisted metal is inside, please post or text me some photos!

I also have a list of parts/accessories from the old engine that were new or recently replaced that you may want to transfer to the new one.
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rmehrIV
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PostPosted: Sun Jan 13, 2013 10:21 pm
Post subject: Re: e39 540i project (photos)

wkohler wrote:
giantkeeper wrote:
Take the hood off Ray Very Happy

No need to take the hood off. You can disconnect the struts and put it vertically.

Thanks for showing the progress.

Welcome guys. Yes I didn't have to take off the hood just disconnect the strut and latched a tie-down to the hood. Looks a little strange but it was safe. It was a lot quicker then taking off the hood, put it back on and then align it.

I was able to get off work today and found some time to take out the engine! When I finished on Friday I only had to take off the exhaust system and disconnect the driveshaft.

Everything went well, got caught on a few things while taking it out but with a few adjustments it wasn't to difficult.


Was able to take off the transmission as well as the clutch. I still need to figure out how to get off the flywheel and pressure plate but that will have to wait for another day.
Found more damage on the block of the engine.
This week I will be working on the car on and off getting it engine prepped to be put back in. Hopefully have it all put back together in a week or two.
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rmehrIV
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PostPosted: Wed Feb 06, 2013 10:47 pm
Post subject: Re: e39 540i project (photos)

Update: This weekend I was able to find some time to transplant the engine back in the car!
Swapped over the flywheel, clutch and transmission.


Got the engine in now I just need to hook everything back up.
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senorcarey
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PostPosted: Thu Feb 07, 2013 8:27 pm
Post subject: Re: e39 540i project (photos) update (2-6)

Good work!
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rmehrIV
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PostPosted: Sat Feb 09, 2013 1:03 am
Post subject: Re: e39 540i project (photos) update (2-8)

Last week when installing the motor my dad noticed that the driver side motor mount ripped. Luckily I had some free time this morning to run to the junkyard and grab some parts.
Old the ripped motor mount.

Also found a fan shroud in good condition to replace the one that was destroyed by the exploding fan clutch.

I was able to get started today putting the engine back together. I was able to get most of the major stuff on and installed. I still have to plug in sensors, change the oil, install the belts, and put the cooling system back in before I can turn the key.

I am hoping that I can finish it this weekend and maybe even get it started.
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SpikeX5
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PostPosted: Sat Feb 09, 2013 3:27 pm
Post subject: Re: e39 540i project (photos) update (2-8)

that mount looked Frankenstein

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02' e53 BMW X5 3.0i
Sport Package, with 03 model body

Brembo Rotors & EBC Red-stuff Pads. Bilstein Shock & Strut Set - PIRELLI SCORPION VERDE
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ambition
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PostPosted: Sat Feb 09, 2013 5:31 pm
Post subject: Re: e39 540i project (photos) update (2-8)

The e39 BMW is the best car built ever PEROID.

BMW got everything right with the e39. It's the perfect all around car. The 540ia is the ultimate daily driver.

If I could get aftermarket warranty coverage for a 2003 540ia sport, I'd buy one. Unfortunately, the car is now too old. Sad


-I didn't like my E46 M3 as much as my E39 540i.
-My Dad's e34 540i was nice, but the e39 is better
-The E60 was a step down (not my opinion, FACT)
-The F10 is nice, but too big and unconnected.

Fix the car and enjoy it.

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rmehrIV
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PostPosted: Tue Mar 12, 2013 11:13 pm
Post subject: Re: e39 540i project (photos) update (2-8)

For the past month I have been extremely busy between school and work. Now that spring break finally came up I got some time to work on the car.
Once I got to the engine in the car I gave the car an oil change, but when I went to tighten down the bolt it had stripped; the bolt wouldn't tighten all the way down or come out. So I then took off the oil pan and replaced it with the one from the blown engine.
When I pulled the oil pan off the blown engine I found a few chunks of metal sitting in the bottom.

All cleaned up.

Once I finally finished replacing oil pan and changed the oil I went to go start the car then....NOTHING. So I did a voltage test on the battery to find out that it was bad. Once I replaced that I went to start the car the...NOTHING. So check all the fuses to find out that they are all fine. The only thing I could come up with would be the start, so I took that off had Checker test it and it failed. After replacing that I tried a third time to start the car and...NOTHING. It would't even turn over. So I gave it some thought and couldn't think of anything else from keeping it from turning over. Once my dad got home I asked him what it could be and he simply asked it I connected the ground wire to the engine. I doubled checked and found out that I hadn't connected it. I then connected the ground and it STARTED!!!
Here is a video:
www.youtube.com/watch?v=DMCkk-epRMY
All done:
All that is left to do before I can drive it is replace the clutch slave cylinder and put the exhaust system on! There are still some stuff that need to get done to the car but it feel good to finally here it start! Thanks for looking.
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