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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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  #201  
Old 06-15-2012, 08:17 AM
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Quote:
Originally Posted by bricas45 View Post
New engine came in!!! This is going to be a long weekend!
Nice! You mentioned that it's a rebuilt one, correct? So all maintenance items are already taken care of?

Mine started leaking oil from somewhere on the front... will look into it this weekend, from the top it looks like the crankshaft seal. I'm hoping it's steering pump though
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  #202  
Old 06-15-2012, 12:22 PM
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Yes it is a full rebuild. New seals and compression tested at around 200 all 8 cylinders....look at your timing chain covers. Getting to that front shaft seal is not easy with that 400+ ft-lb on the bolt there!

Why not put on a brand new clutchmaster fx300 it is easy as anything with the motor off haha!
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #203  
Old 06-15-2012, 01:34 PM
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Also make sure it is oil and not ATF. There is no were it can leak oil at the PS pump. Put a piece of white paper down on clean spot and wait for a drip.
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #204  
Old 06-16-2012, 01:00 PM
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Out with the old! Here is photo of the driver side header.
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #205  
Old 06-16-2012, 09:26 PM
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Some photos of the headers on the new engine. Also showing the clearance around the bell housing.

Last photo I am happy to say is the new engine in its new home. Actually was very easy getting it in. Only had one snag with passenger side header. And I did it by my self which was a little awkward. Maybe ready to give her a start tomorrow!

Tomorrow I will be putting the transmission back on, drive shaft, and exhaust.
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #206  
Old 06-16-2012, 09:31 PM
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Also I know some of you are looking at those valve covers wondering why they are so ugly still. That being taken care of I am powder coating the other set.
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #207  
Old 06-17-2012, 04:08 PM
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Transmission back on and with new mounts the old ones just fell to pieces when coming out. I put in the UUC urethane ones. Transmission went in not to bad took awhile doing it alone to get the angle right and alot of back and forth between top and bottom of car. All back together and started. Battery died so only got one start in today. She wasn't happy to turn over but eventually did...open headers didn't get to the exhaust.
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #208  
Old 06-17-2012, 04:56 PM
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Flug540 Flug540 is online now
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Mein Auto: 1998 BMW 540i 6-spd
Quote:
Originally Posted by bricas45 View Post
Transmission back on and with new mounts the old ones just fell to pieces when coming out. I put in the UUC urethane ones. Transmission went in not to bad took awhile doing it alone to get the angle right and alot of back and forth between top and bottom of car. All back together and started. Battery died so only got one start in today. She wasn't happy to turn over but eventually did...open headers didn't get to the exhaust.
Congrats! You are so close, sounds like if will be back on the road in the matter of hours. The tune is all done at this point? Are you still running stock DME?

BTW, what headers are those?

Can you take a few pictures of your itercooler plumbing? I'm curious to see how you have your pipes routed. I'm getting ready to install an intercooler on my car, leaning toward air-to-air for the sake of simplicity. Went to dyno a couple of times and it showed a dip in the curve at high RPM. The power goes up then steeply falls for a bit, then goes back up and continues to grow. The theory is that the engine senses knocking and cuts the power. I had no idea that I should run higher octane fuel and was running 89 as suggested on the label by the fuel cap. Then switched to 91 and dyno showed that the dip is still there but it moved up. Last week I got 100 fuel and will dyno again to see the impact. I'm hoping if I install the intercooler and cool that air, the dip will be gone.

Quote:
Originally Posted by bricas45 View Post
Look at your timing chain covers. Getting to that front shaft seal is not easy with that 400+ ft-lb on the bolt there! Also make sure it is oil and not ATF. There is no were it can leak oil at the PS pump. Put a piece of white paper down on clean spot and wait for a drip.
Timing covers are dry, it's hard to see with everything mounted at the front, but I'm pretty sure now that I looked that it's the crackshaft seal (plus the lower oil pan). I looked up the procedure and it's not as bad as I thought. Also for my car it's specified to be tightened to 100 Nm and then torqued 60+60+30, which I thought was confusing, why not just say 150? Now I need to find or make the counter holding tool.

Last edited by Flug540; 06-17-2012 at 05:00 PM.
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  #209  
Old 06-17-2012, 09:09 PM
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The tune is really done I will go back for a quick dyno tune to finish it up as it is not done under full boost. As the tune uses an external flasher and it can hold I think 10 different tunes I will probably also try a race fuel tune as well. I think that is 110 octane... I run 93 all the time normally.

The headers are made by Tiger at A1 Muffler in Santa Ana Ca. He made a bunch for the S62 guys on m5forums...I got in on the buy and got these. He sells them for about $1300. I gained a lot of power with those headers I think it came out to just above 20hp and 20ft-lb increase.(289 HP and 305ft-lbs with headers) obviously this was my NA numbers and I can't wait for the SC numbers. A guy I know gained in the 40s on his Dinan SC set up with just headers.

I didn't really finish much more after the battery died and I was pretty beat myself as I worked on her for a long time today...and shacking that tranny into place killed me haha. Unfortunately I am on work travel all this week so nothing really will happen until next weekend. I may wrench a little bit tomorrow morning before my flight.

I will certainly take some photos of the IC set up as I put it all back on. Slow process and I broke one of those quick connects for the coolant system today...so I guess that means I have to order the whole hose just to get the connector (it is on one of the custom hoses.)
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #210  
Old 06-18-2012, 09:28 AM
JimLev JimLev is offline
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Wow, this has really been one long project.
Been meaning to ask you where did you get that 90 O2 adapter?
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2000 540/6 Slightly tweeked...everywhere
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  #211  
Old 06-18-2012, 09:40 AM
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Quote:
Originally Posted by JimLev View Post
Wow, this has really been one long project.
Been meaning to ask you where did you get that 90 O2 adapter?
Yeah one problem after the next really. Can't get her to start again just that one quick. Start on the first one. I am not sure why and don't have time to debug until next weekend.

I got the 90 degree defoulers off eBay they are stainless and were something around $10.
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #212  
Old 06-20-2012, 09:18 AM
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I am pretty confident my starting problem is the crankshaft position sensor. I ordered a new one and will align it this weekend. I didn't go through the alignment procedure on the first one and vaguely remember it looking different from the new ones i see in photos, and that is probably my issue. Will do that then clear all the adaptations with INPA this weekend and will report back. If all is well the car will be back to drivable this weekend. At this point I feel like I have bolted/unbolted everything on this car haha. A lot of blood lost on this car! One thing I do plan to do is a quick oil change on the first one. I want to run the engine to temp with oil and use luqui-moly engine flush for the first runs, and then do an oil change to my usual TWS. I just want to make sure everything is clean and any left over crap from the engine work is gone. Hopefully can get her on the dyno in the next couple of weeks.
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #213  
Old 06-23-2012, 01:35 PM
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I'm happy to say she is running like a champ again!!!! I replaced the crank sensor with a new one, pulled out both cam sensors and cleaned them off, replaced the DME fuses as I was not getting any communication with the DME. I scanned the DME with INPA cleared codes, and cleared adaptations. She started right up after this.
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #214  
Old 06-23-2012, 01:38 PM
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Flug540 Flug540 is online now
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Quote:
Originally Posted by bricas45 View Post
I'm happy to say she is running like a champ again!!!! I replaced the crank sensor with a new one, pulled out both cam sensors and cleaned them off, replaced the DME fuses as I was not getting any communication with the DME. I scanned the DME with INPA cleared codes, and cleared adaptations. She started right up after this.
Congratulations! Now off to dyno!

I dynoed my car last week, turned out pretty good, but I definitely need an intecooler.
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  #215  
Old 06-25-2012, 09:17 AM
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Yes indeed but it will have to wait 2 weeks as I am out of town on a family trip. When I get back I will take those photos of the IC plumbing for you. Modifications were made to fit the piping in (ie cutting plastic parts, my SC had a 90 degree turn welded on with a forged piece so as not to need that silicon couple just after the blower.)

How were your dyno numbers? What boost are you pushing?
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #216  
Old 06-25-2012, 10:28 AM
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Quote:
Originally Posted by bricas45 View Post
Yes indeed but it will have to wait 2 weeks as I am out of town on a family trip. When I get back I will take those photos of the IC plumbing for you. Modifications were made to fit the piping in (ie cutting plastic parts, my SC had a 90 degree turn welded on with a forged piece so as not to need that silicon couple just after the blower.)

How were your dyno numbers? What boost are you pushing?
Thanks a lot!

Attached is a comparison between what I had when I was on 89 octane with the last run with 100 octane. I'm showing the 89 run just to illustrate the dip in the graph, where the DME detects detonation and cuts the power. On the last 100 run it can still be seen, not as pronounced though and in higher RPM. Hoping that it can be resolved with adding the intercooler. Previous to last 100 run was "hot" (right after the first one), the numbers were slightly lower then the last run, but the dip was completely gone, which was nice to see.

I'm running Dinan "stock" pulley, this dyno doesn't have boost logging capability, but the boost should be as advertised per kit up to 8psi.

This weekend replaced my straight pipe with a Dinan muffler, loving the change so far!
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  #217  
Old 06-25-2012, 10:31 AM
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Another fun comparison
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  #218  
Old 07-07-2012, 10:00 PM
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Photos of the IC piping.
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #219  
Old 07-23-2012, 07:54 PM
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so finally got everything back together and running. Starting off burning a bit of oil, but the motor has seated pretty well and there is next to no smoke at the moment. Idle is almost perfect according to INPA which I have attached for you. I have been driving her around slowly breaking in the clutch and making sure the engine runs well throughout rpms. All is great so far! Drives great at the moment. Next step is for the final tune on the dyno.
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars

Last edited by bricas45; 07-23-2012 at 07:57 PM.
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  #220  
Old 07-25-2012, 03:38 PM
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She is back running with the blower on!
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #221  
Old 07-25-2012, 04:39 PM
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Sounds like a real beast, how quick does she feel? M5 quick?
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Dinan Free Flow Exhaust, M5 illuminated shifter and boot, black kidney grills, tinting on back windows, CCFL Angel Eyes, CDV delete, 15mm spaced
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  #222  
Old 07-25-2012, 05:54 PM
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I really haven't driven her hard yet. still breaking everything in...those revs were like 2.5k max. I think I am taking to finish the dyno tune very soon and should have her broken in tomorrow or so. Need to put a few more miles on that clutch before I push her any harder.
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #223  
Old 07-26-2012, 05:48 PM
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bricas45 bricas45 is offline
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Mein Auto: '01 540i6, '94 325is
my list of replaced parts in the last week or so!!!

2 camshaft sensors
1 crankshaft sensor
1 MAF
8 spark plugs
8 coil plugs
2 pre-cat 02 sensors

good thing I am in love with this car!
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #224  
Old 07-29-2012, 10:13 PM
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DinanBimmer DinanBimmer is offline
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Damn, you've gotta be seriously devoted to your car to even think about supercharging it. The thought crossed my mind once, but I've decided to get either an e28 or e34 M5 for my next car after my e39 gives in.
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Dinan Free Flow Exhaust, M5 illuminated shifter and boot, black kidney grills, tinting on back windows, CCFL Angel Eyes, CDV delete, 15mm spaced
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  #225  
Old 07-29-2012, 10:49 PM
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LalaRay LalaRay is offline
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Quote:
Originally Posted by DinanBimmer View Post
Sounds like a real beast, how quick does she feel? M5 quick?
what? The M5 was out of the question when JUST the supercharger was put into the equation.
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2003 ///M5. ~ Jet Black/ Le Mans Blue

RK Supercharged @ 501wheel horsepower
Supersprint Headers,
Evolve Alpha N Tune,
CNS lightweight dm flywheel/Spec clutch,
ST coilovers,
Eibach Rear Sway bar/Beast Power Brackets,
Drilled slotted Rotors/Akebono Euro pads,
Magnaflow 14816 Mufflers

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