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E39 (1997 - 2003)
The BMW 5-Series (E39 chassis) was introduced in the United States as a 1997 model year car and lasted until the 2004 when the E60 chassis was released. The United States saw several variations including the 525i, 528i, 530i and 540i. -- View the E39 Wiki

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  #1  
Old 03-25-2008, 10:20 PM
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Oscswa Oscswa is offline
Oscar
Location: Dallas, TX
 
Join Date: Sep 2004
Posts: 647
Mein Auto: 330i Sport
OE M5 Bumper Conversion on a 540i

Well I have started to collect everything I need for the front bumper conversion.

I was lucky enought to get an OE M5 Bumper that just needed to be repainted. I just have a few questions (reguards to parts) for anyone that has done this conversion on their 540i. I have done an extensive search and I only seem to find a few posts with a full conversion but they have been on 530's.

Can I use my existing Air Duct, Oil Cooler (540) and duct supports (540) for the belly pan to work or do I need to buy all new parts? I know you have to buy all new parts for the 530 but what about the 540?

M-TECH FRONT BUMPER PARTS LIST
51-11-2-695-762 Air Duct, Oil Cooler (Will my current 540 one work?) Tyrone: don't have one currently and don't need this
51-71-7-892-297 bracket/support duct (Will my current 540 one work?) Tyrone: Need this
51-71-7-892-298 bracket/support duct (Will my current 540 one work?) Tyrone: Need this
51-11-2-498-507 Front Bumper (GOT IT, needs additional hole made for PDC)
51-71-2-498-939 Front Air Duct (Plan on modifing existing one)
51-11-7-890-013 Air Duct Left (Not sure if I need this yet)
51-11-7-890-014 Air Duct Right (Not sure if I need this yet)
51-11-2-693-539 Front Tow Flap (Will my current 540 one work?) Tyrone: Need this
51-11-2-494-193 Front Buffer Strip Left (GOT IT, painted)
51-11-2-494-194 Front Buffer Strip Right (GOT IT, painted)
51-11-8-159-361 Support Left (Old one can be reused)
51-11-8-159-362 Support Right (Old one can be reused)
51-11-8-191-149 Gasket (GOT IT)
51-11-2-496-285 M5 mesh Grille (GOT IT)
51-11-2-694-214 License plate frame (required by state, but I am not doing it)
61-13-0-007-272 Contact To Fog Lamp x4 (Not sure if I need this yet) Tyrone: Don't need these on 01+
61-13-8-364-498 Plug For Fog Lamp x2 (Not sure if I need this yet) Tyrone: Need this
63-17-7-894-017 Fog Lamp Left CLEAR LENS (GOT IT, ebay replica)
63-17-7-894-018 Fog Lamp Right CLEAR LENS (GOT IT, ebay replica)
51-11-2-496-283 Fog Light Frame left (GOT IT)
51-11-2-496-284 Fog Light Frame right (GOT IT)
51-71-2-694-899 Wheel liner/support Right (GOT IT)
51-71-2-694-832 Wheel liner/support Left (GOT IT)
51-71-2-498-988 Screening (540/M5) (GOT IT)

Tyrone also added:
You'll also need the following
10 axial clips to secure the grid to the bumper
4 additional screw plugs for the belly pan
2 fog light bolts and body nuts
8 bolts and body nuts for the fender liners

Here are some pics of the parts I have collected in last 3 weeks.






As always any help with my question is greatly appreciated. I will keep posting on the progress with some more pics.
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01 540i Sport
06 330i Sport
01 530i Sport
01 540i Sport 6spd


Last edited by Oscswa; 03-25-2008 at 11:19 PM.
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  #2  
Old 03-25-2008, 10:24 PM
Smittys540 Smittys540 is offline
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Doing the same. Thx for starting the thread Looke like you are of to a strong start.
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  #3  
Old 03-25-2008, 10:27 PM
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Oscswa Oscswa is offline
Oscar
Location: Dallas, TX
 
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Quote:
Originally Posted by Smittys540 View Post
Doing the same. Thx for starting the thread Looke like you are of to a strong start.
Thanks, I think we just need to find someone out there that has done the full conversion on a 540. If not I will have to pull my current bumper apart and see if the current support brackets will work (hopefully it won't have to come to that).
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  #4  
Old 03-25-2008, 10:32 PM
Smittys540 Smittys540 is offline
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I am asking around and will post any info I come across. How much did the factory bumper set ya back? Oh and the paint, how much was that? It looks awesome!
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  #5  
Old 03-25-2008, 10:37 PM
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Oscswa Oscswa is offline
Oscar
Location: Dallas, TX
 
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Quote:
Originally Posted by Smittys540 View Post
I am asking around and will post any info I come across. How much did the factory bumper set ya back? Oh and the paint, how much was that? It looks awesome!
Thanks and your going to hate me when I say this...$0.00

The bumper was a gift and a good friend of mine owed me a favor and had both the bumper and strips painted by his best painter, but he did tell me that normally it's around $200 for prep and paint.
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01 540i Sport
06 330i Sport
01 530i Sport
01 540i Sport 6spd


Last edited by Oscswa; 03-25-2008 at 10:40 PM.
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  #6  
Old 03-25-2008, 10:51 PM
Smittys540 Smittys540 is offline
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Wow!!! U lucky Dog
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  #7  
Old 03-25-2008, 10:56 PM
Tyrone Tyrone is offline
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Can I use my existing Air Duct, Oil Cooler (540) and duct supports (540) for the belly pan to work or do I need to buy all new parts? I know you have to buy all new parts for the 530 but what about the 540?

M-TECH FRONT BUMPER PARTS LIST
51-11-2-695-762 Air Duct, Oil Cooler (Will my current 540 one work?) don't have one currently and don't need this
51-71-7-892-297 bracket/support duct (Will my current 540 one work?) Need this
51-71-7-892-298 bracket/support duct (Will my current 540 one work?) Need this
51-11-2-498-507 Front Bumper (GOT IT, needs additional hole made for PDC)
51-71-2-498-939 Front Air Duct (Plan on modifing existing one)
51-11-7-890-013 Air Duct Left (Not sure if I need this yet)
51-11-7-890-014 Air Duct Right (Not sure if I need this yet)
51-11-2-693-539 Front Tow Flap (Will my current 540 one work?) Need this
51-11-2-494-193 Front Buffer Strip Left (GOT IT, painted)
51-11-2-494-194 Front Buffer Strip Right (GOT IT, painted)
51-11-8-159-361 Support Left (Old one can be reused)
51-11-8-159-362 Support Right (Old one can be reused)
51-11-8-191-149 Gasket (GOT IT) Get another. 3 cut pieces of these are used
51-11-2-496-285 M5 mesh Grille (GOT IT)
51-11-2-694-214 License plate frame (required by state, but I am not doing it)
61-13-0-007-272 Contact To Fog Lamp x4 (Not sure if I need this yet) Don't need these on 01+
61-13-8-364-498 Plug For Fog Lamp x2 (Not sure if I need this yet) Need them
63-17-7-894-017 Fog Lamp Left CLEAR LENS (GOT IT, ebay replica)
63-17-7-894-018 Fog Lamp Right CLEAR LENS (GOT IT, ebay replica)
51-11-2-496-283 Fog Light Frame left (GOT IT)
51-11-2-496-284 Fog Light Frame right (GOT IT)
51-71-2-694-899 Wheel liner/support Right (GOT IT)
51-71-2-694-832 Wheel liner/support Left (GOT IT)
51-71-2-498-988 Screening (540/M5) (GOT IT)

You'll also need the 10 axial clips to secure the grid to the bumper, 4 additional screw plugs for the belly pan, two fog light bolts and body nuts, 8 bolts and body nuts for the fender liners, and headlight washers to fill the voids if you don't already have them. I can't think of anything else at the moment.
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  #8  
Old 03-25-2008, 11:09 PM
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Oscswa Oscswa is offline
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Location: Dallas, TX
 
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Thanks Tyrone, as always you are all knowing!

I will go ahead and order the parts you said I am still needing. About the Gasket, I got a brand new one from the dealership but it's one long single piece that fits the entire top of the bumper from end to end. Do I need another gasket for another area of the bumper?
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01 530i Sport
01 540i Sport 6spd

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  #9  
Old 03-25-2008, 11:29 PM
Tyrone Tyrone is offline
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It's natural to place that gasket as one long piece at the top, but the proper way to do it is in two pieces. Cut one gasket into two 1052mm pieces and space them symmetrically at the top of the bumper. You should have about a ~2cm gap in the middle between the two pieces for water drainage.

You'll use the second gasket for a 984mm section that goes along the bottom center of the bumper where the belly pan makes contact. You'll instantly be able to identify this space once you look (your third picture above shows it), so no need to measure exactly and cut. You could place the gasket on the bumper and cut to size once you have an exact fit. This is important to keep the belly pan from making noises in this contact area.
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  #10  
Old 03-25-2008, 11:39 PM
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jvcajita jvcajita is offline
e39 m5 touring aspirant
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I'm not as detailed oriented as "Doctor Tyrone" (got mad props for you bro!), yet I hope I can help you a lil bit with this DIY...

http://www.bimmerfest.com/forums/sho...d.php?t=234698

Cheers! And I love the fact you stick true to OEM!!! =)
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  #11  
Old 03-26-2008, 08:18 AM
SaveItK SaveItK is offline
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Oscar, I've done this conversion and used my OEM brackets.
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  #12  
Old 03-26-2008, 01:14 PM
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Oscswa Oscswa is offline
Oscar
Location: Dallas, TX
 
Join Date: Sep 2004
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Quote:
Originally Posted by jvcajita View Post
I'm not as detailed oriented as "Doctor Tyrone" (got mad props for you bro!), yet I hope I can help you a lil bit with this DIY...

http://www.bimmerfest.com/forums/sho...d.php?t=234698

Cheers! And I love the fact you stick true to OEM!!! =)
Thanks, I have looked at your post in the past and it has been very helpfull.

Quote:
Originally Posted by SaveItK View Post
Oscar, I've done this conversion and used my OEM brackets.
Kevin, good to hear from you. I thought you got an aftermarket bumper? I thought with an aftermarket bumper you don't need the belly pan, but I am very interested in hearing how you used the OEM brackets.
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01 530i Sport
01 540i Sport 6spd

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  #13  
Old 04-04-2008, 10:55 PM
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Oscswa Oscswa is offline
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Location: Dallas, TX
 
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I wanted to give an update on my progress.

Today I got the last 2 pieces needed for the bumper conversion:
51-71-7-892-297 bracket/support duct and 51-71-7-892-298 bracket/support duct
and on Saturday, April 5th I will be picking up the rest of clips and nuts from the dealer.

Saturday's Agenda (April 5th)
Arrive at brothers around 1pm
Go with my brother to BMW in his car (need to let my car cool off) and pick up the folowing parts.
Brake Pads (old ones have 70k miles on them)
Rotors (old ones have 140k miles on them)
Intake re-seal kit (preventative maintanance)
clips and nuts (for bumper)
Start tearing stuff apart by 2:30pm and hopefully be done by 6pm, cleaned up and ready for dinner by 7:30pm

It will be a busy day and I will take plenty of pictures to post here with before and after.
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01 540i Sport
06 330i Sport
01 530i Sport
01 540i Sport 6spd

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  #14  
Old 04-05-2008, 11:53 AM
Rgol Rgol is offline
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I did the conversion on a 528i. There are some different parts between the two, but they are not that different. You may find that reusing some parts may or may not work. Removing yoru old bumper may stress or even break a few things. I bought all new parts and found that everyone was used or replaced, especially small screws etc. I even had to go to the dealer and get some additional screws that the kit missed.
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  #15  
Old 04-05-2008, 08:13 PM
SaveItK SaveItK is offline
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And? Where are the photos?
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  #16  
Old 04-06-2008, 01:19 PM
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Oscswa Oscswa is offline
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Location: Dallas, TX
 
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I finished up the bumper upgrade, every single part I listed above I used. I am missing the foglights, tow cover, and the drivers side fog cover. I had the foglights returned last week as they were damaged (probably shipping), they guy I bought them from is sending a new set. The tow cover is being painted and the drivers side fog cover that I have on their right now is for the 525 or 530, I need to make a trip back to the dealer and tell them they ordered the wrong part and get the me 540 or M5 version.

I also replaced the front rotors, pads and a small piece that was causing the intake leak. While we had the car off the ground, my brother found a few other things needing replacement. I can't say as I don't remember what exactly but I do remember him saying something about a front and real seal and that the tranny has to come out for it. So I start up another tread next month detailing those replacements.









Replacing the intake seal that caused the leak



This is what caused the leak




Here are the rotors being replaced and you can see in the background leakage that needs to have the tranny pulled which is going to be fixed next month


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06 330i Sport
01 530i Sport
01 540i Sport 6spd


Last edited by Oscswa; 04-06-2008 at 01:22 PM.
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  #17  
Old 04-06-2008, 01:33 PM
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1bad540 1bad540 is online now
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That bumper looks great.....good job
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  #18  
Old 04-06-2008, 01:36 PM
98bmw528i 98bmw528i is offline
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Very awesome!
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  #19  
Old 04-06-2008, 05:00 PM
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bimmerd00d bimmerd00d is offline
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Looks good dude, love that color as always. Intake leaks are always fun.
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  #20  
Old 04-07-2008, 09:58 AM
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Oscswa Oscswa is offline
Oscar
Location: Dallas, TX
 
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Quote:
Originally Posted by bimmerd00d View Post
Looks good dude, love that color as always. Intake leaks are always fun.
Yea, I am glad it was an easy fix.

Now all I need now is the rear bumper.....

I had some guy yesterday that pulled infront of me at the gas station walk over and ask me if I had my car custom painted. I said "no, it's a factory color why do you ask." He then said "I didn't know they made the 03 540 in red." I then went on to tell him that I had a bumper replaced and blah, blah, blah...he had just traded in his 02 525 for an X5.
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01 530i Sport
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Last edited by Oscswa; 04-07-2008 at 10:00 AM.
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  #21  
Old 04-07-2008, 10:21 AM
Ben Carufel Ben Carufel is offline
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Oscar,

Your brother was talking about the rear main seal. My girlfriend and I just replaced the one on my '00 528i Touring a few weeks ago.

I'll ask her if the M62 engine is the same, but I know that for the M52, BMW recommends a special tool to install the new RMS. It's not necessary -- you can hold the seal in place and tap it in with a mallet. She will probably know whether the M62 can be done like that as well.
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  #22  
Old 04-14-2008, 09:40 PM
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Oscswa Oscswa is offline
Oscar
Location: Dallas, TX
 
Join Date: Sep 2004
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Finished up the bumper today. I installed the foglights and modified the front grill for brake ducts, I used $2 4" Casino Cup Holders. I decided to go black as it looked more OEM and I didn't like the chrome as well as the price for the Active Autoworks version.

I am still waiting on the tow hook, but overall I think it looks good. I took some night pictures as I just finished washing it.





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  #23  
Old 04-14-2008, 11:35 PM
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rivercity rivercity is offline
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Your car look great..........Hey, I hang out at Jenny Craig as well to pick up the chics
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  #24  
Old 04-15-2008, 09:43 AM
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Oscswa Oscswa is offline
Oscar
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Funny, I didn't even notice Jenny Craig in the background
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01 540i Sport 6spd

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  #25  
Old 04-15-2008, 11:46 AM
kaptom540 kaptom540 is offline
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looking good .. i wonder how black moldings would look .. now you have to change your sig ..
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