E39 540i Daily Wagon

Discuss Non-E30 BMW's in here - No selling!

Moderator: martauto

DanThe
E30 Zone Team Member
E30 Zone Team Member
Posts: 28649
Joined: Sat Sep 10, 2005 11:00 pm
Location: Staffs

Post Sun Jun 15, 2014 12:19 am

I thought it was about time I did a bit of a thread, bought this back in December 2012 off Jimbo on here, 72,000 miles, 3 previous owners and plenty of history, very well kept TBH

Image

Image

Image

The plan was to get it gassed and give it a good going over before putting it into daily use, I used it for a few weeks before getting very tired of seeing these messages -

Image

Image

So laid it up for a couple of months while I got the LPG parts ready.
With help fro Grrrrr on here I had a Stag front end kit bought direct from Poland at a very nice price, the tank however took a lot longer to sort, as I wanted the biggest tank possible, and a bit more..... My previous LPG chariot would only take 50 litres of gas, and as such you soon get fed up of filling the thing, so I was aiming for 100 litres especially considering the MPG of this beast, after stripping the boot out, remounting the SLS airpump above the battery and cutting plenty of useless steel out of the spare wheel well id measured up and found a single hole tank that would 'just about' fit with a bit of persuasion, only trouble was nobody stocked it, I eventually found an LPG shop run by a Polish chap who agreed to import me a tank, 6 weeks later the 108 litre total capacity lump landed and I grafted it in

Image

Image

Image

Throw in a BMW factory fit detachable towbar while were on :D

Image

Here is where the gas goes in

Image

With the adaptor fitted (steel thread innit)

Image

With some careful bending of the float level arm I can now fill to 100 litres :cool:

At the business end of the car id stripped the inlet manifold off to fit the injector nozzles

Image

Whilst in there I took the cam covers off to fix the oil leaks with new gaskets and bolt seals and a tube of loctite gasket sealer
Nice and clean in here -

Image

Image

I also removed the lower sump to have a potential wipe round, but it proved worthless as the bottom end was also just as clean as the top, no nasty stains anywhere, thanks for the servicing to the previous owners 8)

Random shot of a proper alloy T piece

Image

Also dropped the auto box sump, changed the filter and expensive oil there.
Fuel filter, air, oil, pollen filters etc etc

And this is how the engine bay looks with gas conversion complete

Image

Not much different apart from the reducer hiding down behind the headlight

Image



Next job was the brakes, well past their best with very little meat left on the discs I stripped them all off and found the rear back plates were also shot

Image

To change them the wheel bearings need to be removed

Image

Replaced with new dealer supplied back plates which I had sandblasted and powdercoated to give them a better than average chance

Image

New wheel bearings

Image

Image

Image

I stripped down the brakes and had them de-rusted and zinc plated along with the new discs

Image

The rear calipers are cast aluminium so I had them stripped of corrosion and anodised grey, built up -

Image

Now the brakes were looking better than new, I couldnt fit the 7j 16's back on, they felt quite loose with spirited driving to say the least!

So a set of staggered 8j and 9j 17" M sport wheels were bought and I had them refurbished at a local wheel specialist

Image

Much better :cool:

Image

Image

I bought some privacy shades from vanstyle

Image

Image

Image

Cant fault them at all, very nice fit and quality parts.

And finally, before the first real outing I planned to the Isle of Wight I changed the leaky condenser rad so we could have some cold air blowing inside
Blatantly obvious hole right in the middle

Image

Not a bad job to do with the rad out of the way

Image

But with the rad removed it also was screaming "replace me"

Image

Its now at just over 90,000 miles and another recent oil/filter change (10,000 mile intervals for my cars) and air filters, currently averaging 13.5mpg on the gas, at 59 pence per litre its the equivalent of approx 30mpg on petrol

Image

Will add more soon
Speedtouch
Old Skooler
Old Skooler
Posts: 14100
Joined: Tue Feb 14, 2006 11:00 pm
Location: Canterbury

Post Sun Jun 15, 2014 12:44 am

Looks good, like the colour. Does the zinc coating wear off the discs as you use the brakes?
///M aurice
ECU Upgrade EPROM Chips, £40 posted within the UK. Note these are not Zone chips.
viewtopic.php?f=6&t=279421
Jesus325iTouring
Frog freak !
Frog freak !
Posts: 11356
Joined: Sun Jan 09, 2005 11:00 pm
Location: Omnipresent!

Post Sun Jun 15, 2014 9:50 am

Good write up there Dan :D Very appealing chariot that :cool:
Image

X5 V8 for thrills, CRV for chills, Range Rover P38 V8 for sooooo much aggravation...
B7
E30 Zone Team Member
E30 Zone Team Member
Posts: 15846
Joined: Tue Feb 13, 2007 11:00 pm
Location: Surrey / West Sussex

Post Sun Jun 15, 2014 1:22 pm

Top work Dan. Very nice.
B7's Motto. "If it's French, BURN IT!!!!!!"
Jon_Bmw
Dangerous when thinking
Dangerous when thinking
Posts: 7606
Joined: Tue Jan 11, 2005 11:00 pm
Location: Salisbury

Post Sun Jun 15, 2014 5:41 pm

I loved mine. But as a daily at 24mpg (being driven like an old granny) it had to go. I couldn't face doing another LPG conversion as I'm too lazy these days.

You've done a nice job on that dan. I always wanted a sport touring as the SE bumpers are abit plain Jane.

ETA: if your rad looked like that it wasn't far off going. As per Andyboys advice I would change the heater matrix hoses on the passenger side bulkhead. They will go at some point and it will cook the engine if the wife is driving and fails to notice the temp gauge rapidly rising. I remember mine being 'welded' on as the cooling system runs hot on the V8. For the life of me I can't remember if it is one or two hoses.
jimbom30cab
Tech 1 freak
Posts: 7634
Joined: Mon Oct 12, 2009 11:00 pm
Location: in the garage

Post Sun Jun 15, 2014 6:03 pm

Nice work there Dan.

So just to fill in the history of this motor. It was a BMW demonstrator at a dealership near leeds when new. A local oldish bloke bought it from the dealers, his name is on the bill of sale in the docs pack. He paid £40,000 for it and also part exchanged two 36s with a cash top up. He then drove it locally until early 2009 when he sold it locally to a chap in Leeds. It was him I bought it from, he only had it about 6 months and his wife said it was too big and thirsty for local trips. I flew up to Leeds Bradford airport in Aug 09 and paid £4,400 for it.

I'll never forget the drive back to Hampshire on that quiet hot august evening and the M1 was a real joy with the 4.4 v8 power. If i remember right it had 48k ish miles on the clock then and really was "as new" from the appearance.

The only problem I had with it was an air bag blowing whilst we were on holiday in South Wales. It went with a bang and as i was too tight to put it in a garage we drove home with it on the rear stops. Proper lowered style.

I heard a few horror stories about the 540i but i never had any problems with it and spent a bit of money improving it. The pixel repair and a few others.

A lovely car indeed and joy to drive. If i remember right it would touch 110mph in 3rd gear.

Very glad to see its been well looked after, nice work Dan.
Last edited by jimbom30cab on Sun Jun 15, 2014 9:37 pm, edited 2 times in total.
DanThe
E30 Zone Team Member
E30 Zone Team Member
Posts: 28649
Joined: Sat Sep 10, 2005 11:00 pm
Location: Staffs

Post Sun Jun 15, 2014 9:10 pm

Nice one Jim, the supplying dealer was Preston Farm, previously called Cowies which is on the same road as Dezzy's tyre place oop north in Stocton-on-Tees :D
bss325i
E30 Zone Team Member
E30 Zone Team Member
Posts: 24536
Joined: Sat Jan 20, 2007 11:00 pm
Location: London/Surrey

Post Sun Jun 15, 2014 9:18 pm

Peado'd daily.

Nice work! :cool:
http://www.bmrperformance.co.uk

BMW and MINI specialist - Gatwick
DanThe
E30 Zone Team Member
E30 Zone Team Member
Posts: 28649
Joined: Sat Sep 10, 2005 11:00 pm
Location: Staffs

Post Sun Jun 15, 2014 9:23 pm

Jon the top hose blew on easter weekend, it had been losing coolant from a small dribble from the expansion tank/level sensor, I remembered at the time the coolant level warning had come on a couple of weeks previous but then didnt come on since so I never checked it! First thing I noticed was the needle rising a couple of mm above the half way, so turned the aircon off, heater on full and switched off, coasted round the corner into a petrol station and ended up bodging the hose with 2 rolls of insulation tape before limping home 50 odd miles, stopped every 7 or 8 miles to refill 8 litres :cry:

So ive now fitted a new expansion tank, level sender and pressure cap.
I also replaced the water pump the other week as that was showing quite a fair amount of play.

This Friday just gone I replaced the engine mounts, id noticed the engine vibrating at idle and the odd shunt through the gear box every now and again, so a pair of Febi Bilstein were fitted, they have made a big difference! I stick the boot in on a daily/regular basis as you can probably tell by my average MPG winkeye and with 300 odd Lbft to soak up its no wonder they gave up, you can see how worn out they were

Image

Image
DanThe
E30 Zone Team Member
E30 Zone Team Member
Posts: 28649
Joined: Sat Sep 10, 2005 11:00 pm
Location: Staffs

Post Sun Jun 15, 2014 9:26 pm

I also plucked up the courage to fit the other rear ABS sensor, I did the one a couple of months ago, what a coooont of a job :cry:
Simon13
The longest resto in the world !
Posts: 22697
Joined: Mon Jan 10, 2005 11:00 pm
Location: Camberley, Surrey don't u know

Post Sun Jun 15, 2014 11:19 pm

they're a real grunty old thing, like a proper v8 motor. I remember the test drive very well when you bought it and we had a quick blast down the A3.

Nice work.

Anywork on the exhaust for more noises?
DanThe
E30 Zone Team Member
E30 Zone Team Member
Posts: 28649
Joined: Sat Sep 10, 2005 11:00 pm
Location: Staffs

Post Sun Jun 15, 2014 11:26 pm

I did originally cut out one of the back boxes and it sounded much better, but I changed the whole system last autumn as the front pipe joints had gone and the middle box had rotted out on the top (weird I thought)
I picked up a system for £40 that had a custom centre joint made in stainless and tig welded, the standard joint is shite! It also has aftermarket cats, so I sold the original cats for £100 odd.
Ive not yet got round to it, but I do plan on getting rid of both back boxes, im catching up on jobs that need to be done now so it shouldnt be long 8)
DanThe
E30 Zone Team Member
E30 Zone Team Member
Posts: 28649
Joined: Sat Sep 10, 2005 11:00 pm
Location: Staffs

Post Mon Jun 16, 2014 1:05 pm

Jon_Bmw wrote:I loved mine. But as a daily at 24mpg (being driven like an old granny) it had to go. I couldn't face doing another LPG conversion as I'm too lazy these days.

You've done a nice job on that dan. I always wanted a sport touring as the SE bumpers are abit plain Jane.

ETA: if your rad looked like that it wasn't far off going. As per Andyboys advice I would change the heater matrix hoses on the passenger side bulkhead. They will go at some point and it will cook the engine if the wife is driving and fails to notice the temp gauge rapidly rising. I remember mine being 'welded' on as the cooling system runs hot on the V8. For the life of me I can't remember if it is one or two hoses.
Did you change yours Jon?
I was having a poke around this morning after the check coolant bonged again and found this at the back of bank 1 -

Image

Goes round the back of the engine to the aux/elec pump on the pass side
Its probably been weeping since the overheating at easter, I will have a replacement tomorrow at £25 odd

As you say the running temp of these is crazy, 104° C :mad:
You can see why the hoses explode without warning...
Jon_Bmw
Dangerous when thinking
Dangerous when thinking
Posts: 7606
Joined: Tue Jan 11, 2005 11:00 pm
Location: Salisbury

Post Mon Jun 16, 2014 7:31 pm

DanThe wrote:
Jon_Bmw wrote:I loved mine. But as a daily at 24mpg (being driven like an old granny) it had to go. I couldn't face doing another LPG conversion as I'm too lazy these days.

You've done a nice job on that dan. I always wanted a sport touring as the SE bumpers are abit plain Jane.

ETA: if your rad looked like that it wasn't far off going. As per Andyboys advice I would change the heater matrix hoses on the passenger side bulkhead. They will go at some point and it will cook the engine if the wife is driving and fails to notice the temp gauge rapidly rising. I remember mine being 'welded' on as the cooling system runs hot on the V8. For the life of me I can't remember if it is one or two hoses.
Did you change yours Jon?
I was having a poke around this morning after the check coolant bonged again and found this at the back of bank 1 -

Image

Goes round the back of the engine to the aux/elec pump on the pass side
Its probably been weeping since the overheating at easter, I will have a replacement tomorrow at £25 odd

As you say the running temp of these is crazy, 104° C :mad:
You can see why the hoses explode without warning...
Dan,

Yes I changed mine on the advice on Andyboy and I am pretty sure it wasn't that hose.

I will try and find a library photo of it. I'm sorry I can't remember better!

I also changed the rad top hose like you as it felt 'squishy' when I did the rad.
Jon_Bmw
Dangerous when thinking
Dangerous when thinking
Posts: 7606
Joined: Tue Jan 11, 2005 11:00 pm
Location: Salisbury

Post Mon Jun 16, 2014 7:55 pm

I think it was the second hose on this page:

http://forums.bimmerforums.com/forum/sh ... rt-Numbers

I guess the late cars use the first hose and the early ones use the second hose. You are best off checking with Andyboy though.

Definitely passenger side and it attached to a stub on the bulkhead. It was quite short, circa 8-12" long if it was straightened.
DanThe
E30 Zone Team Member
E30 Zone Team Member
Posts: 28649
Joined: Sat Sep 10, 2005 11:00 pm
Location: Staffs

Post Mon Jun 16, 2014 8:07 pm

TBF the hoses on mine look to be in very good condition, which is why I didnt replace anything originally, if this hose that comes tomorrow looks simple enough I will probably buy some flexi silicone hose and use that instead
DanThe
E30 Zone Team Member
E30 Zone Team Member
Posts: 28649
Joined: Sat Sep 10, 2005 11:00 pm
Location: Staffs

Post Fri Jun 20, 2014 10:00 pm

So rather than fix the cooling system, today I decided to cut the back boxes off :)

A length of stainless tube, bit of a bend and some welding later -

Image

Who the f00k said this was a good idea? :mad:

It now sounds like a council E30, booming and echoey :cry:
Simon13
The longest resto in the world !
Posts: 22697
Joined: Mon Jan 10, 2005 11:00 pm
Location: Camberley, Surrey don't u know

Post Fri Jun 20, 2014 10:34 pm

its a v8.
DanThe
E30 Zone Team Member
E30 Zone Team Member
Posts: 28649
Joined: Sat Sep 10, 2005 11:00 pm
Location: Staffs

Post Fri Jun 20, 2014 10:52 pm

It is indeed, but any exhaust that sounds 'hollow' sounds crap IMO
I will have to get a straight through box made up to go in that new bit
Simon13
The longest resto in the world !
Posts: 22697
Joined: Mon Jan 10, 2005 11:00 pm
Location: Camberley, Surrey don't u know

Post Sat Jun 21, 2014 8:41 am

so like a knackered scorpion? they sound the best
DanThe
E30 Zone Team Member
E30 Zone Team Member
Posts: 28649
Joined: Sat Sep 10, 2005 11:00 pm
Location: Staffs

Post Sat Jun 21, 2014 2:16 pm

Yep, reet council
pacerpete
E30 Zone Team Member
E30 Zone Team Member
Posts: 18168
Joined: Sun Jan 23, 2005 11:00 pm
Location: Iver heath. South bucks.

Post Sat Jun 21, 2014 2:37 pm

Simon13 wrote:so like a knackered scorpion? they sound the best

Spoken like a true footballist ! :eek:
Andyboy
Alpina Colada
Posts: 12578
Joined: Mon Sep 11, 2006 11:00 pm

Post Sat Jun 21, 2014 8:08 pm

Apparently, a good mod on these is to bin the mapped thermostat and fit the old E34 type standard version. The mapped stat keeps the engine at a very high temp and the pressure cap is mega strong to keep it from exploding - which they do when they get old. The E34 stat lowers the temps by around 10 degrees and that makes life a lot easier for the cooling system. The plug for the stat can just be tie wrapped up out of the way - you won't get any warning lights.
DanThe
E30 Zone Team Member
E30 Zone Team Member
Posts: 28649
Joined: Sat Sep 10, 2005 11:00 pm
Location: Staffs

Post Sun Jun 22, 2014 10:44 am

I had thought about that Andy, I priced up a new elec stat and decided I wasnt buying one!

Taking some pressure off the extra coolant joints for the LPG system can only be a good thing.

On another note I recently changed the handbrake cables, I struggled to get a pair of quality aftermarket cables and ended up ordering in a set of Pagid cables from ECP.
I now know why nowhere stocks them,,,, because nobody in their right mind would want to do the job :mad:

The rear hub carriers are cast aluminium and the cable glands are steel, never a good mix

Old and new-

Image

The hole

Image

The problem is, to get a drift on the cable end you have to remove the rear wheel bearings as the hub is in the way :evil:

The other end of the cable is no fun either, exhaust off, heat shields dropped onto the prop and bent a bit just about gives enough room to get your fingers at the body tubes for the cables.
Biggest tip I can give here though is to never buy Pagid cables, they are shite and do not fit through the body tubes

Pagid cable at the top, BMW cable underneath

Image

The thread is so long on the pagid cable it wont go round the bend in the body tube, so I had to cut about 5 threads off, also note there is no square section on it, so when you are adjusting it the bloody cable spins :x

Definitely one of those jobs that gives you tourettes :cursin:
Simon13
The longest resto in the world !
Posts: 22697
Joined: Mon Jan 10, 2005 11:00 pm
Location: Camberley, Surrey don't u know

Post Sun Jun 22, 2014 11:13 am

the one pagid i bought from ecp for my e34 was similar, but the job is no where near as sad. V.similar to doing an e30 cable
DanThe
E30 Zone Team Member
E30 Zone Team Member
Posts: 28649
Joined: Sat Sep 10, 2005 11:00 pm
Location: Staffs

Post Tue Jun 24, 2014 10:45 pm

Check out the councilness -

Image

Ive put one of the standard boxes back in and it sounds much more civilised

Image
Duke137
Married to the E30 Zone
Married to the E30 Zone
Posts: 7207
Joined: Sat Aug 29, 2009 11:00 pm

Post Tue Jun 24, 2014 11:08 pm

More council activity then mate, that bent pipe section looks like one of the down-pipes from your E30 - 24v manifold kit :chuckle:
How do you pronounce 'either'? I say 'either', but some say 'either'. Either is correct.
DanThe
E30 Zone Team Member
E30 Zone Team Member
Posts: 28649
Joined: Sat Sep 10, 2005 11:00 pm
Location: Staffs

Post Tue Jun 24, 2014 11:12 pm

No its actually 2.5 inch tube, still smaller than the 540 system which is around 69mm so had to be stretched quite a bit!

It will be on ebay shortly :)
goosiegander
Zonegoose
Posts: 2544
Joined: Sun Nov 19, 2006 11:00 pm
Location: East Anglia

Post Tue Feb 23, 2016 3:18 pm

Good read there Dan...
Jon_Bmw
Dangerous when thinking
Dangerous when thinking
Posts: 7606
Joined: Tue Jan 11, 2005 11:00 pm
Location: Salisbury

Post Tue Feb 23, 2016 7:34 pm

Dan I did the rear muffler delete to mine and after around 5k miles I put it back. It did sound TVR'esk but it did drone a bit. People were always looking around for some sports car!

I then did the same as you, took away the expansion chamber and just had the one box. That was before doing a 2.5k mile jaunt around Europe. I just couldn't put up with the drone of the delete.

I miss my 540i... :cry:
DanThe
E30 Zone Team Member
E30 Zone Team Member
Posts: 28649
Joined: Sat Sep 10, 2005 11:00 pm
Location: Staffs

Post Tue Feb 23, 2016 8:05 pm

Ive been around a couple with both rear boxes removed but retaining the standard cats and they don't sound as bad, the main reason mine was so loud is because I have aftermarket cats fitted which are much more free-flowing.

Loads of updates to write about, pictures are somewhere.... now up to about 122,000 miles so total milage with me is 50,000