SCHLEPN | The E39 540itA Story

YoungCR

Hey look its Bill! Will the 540i exhaust bolt up or are the downpipes bigger on the S62?

patsbimmer1

Yesssss

DrLeadFoot

YoungCR said:

Hey look its Bill! Will the 540i exhaust bolt up or are the downpipes bigger on the S62?

That's Bill! He came over to Mike's twice to kick it and help out a bit! Between Mike and Bill there is a lot of knowledge in that garage!

DrLeadFoot

I'm going to have Structure Fabrication and Design do the exhaust. Thinking 2 mufflers and high flow cats or 3 mufflers. Need something mild for family road trips!

B C

YoungCR

Just for ideas these are the phases we've gone through on my brother's 540i's.

Phase 1: Dinan Muffler (stock but gutted) sounded more or less stock.

Phase 2: Cut off the Dinan Muffler. Sounded great, loud enough at idle but perfect for cruising. About 1/2 throttle it was just right and no drones at all. Just the cats and resonators

Phase 3: No resonators, straight pipes. Sounded like a tractor and it droned. Absurdly loud at WOT lol.

Phase 4: Full Super Sprint catback w/ resonator and muffler. Slightly louder than stock but not by much. Opens up a little more WOT.

Phase 5: trying to go back to phase 2. Either unbolting the muffler and replacing or gutting the cats.

TLDR I'd recommend performance resonators somewhere. 3 Muffflers might be overkill. Electric cut outs would enable best of both worlds too.

Jdesign

Dude, you guys absolutely hammered through this. I love your evil laughter in the videos!!

I vote high flow cats and dual resonators. If that's too loud then delete the resonators and run high flow mufflers. As long as the tips go out past the rear bumper and dont turn down, it wont be as loud in the cabin.

Chubs has built some nice exhaust set ups, im sure you will figure out the best option.

DrLeadFoot

Took it for a little test drive yesterday afternoon after bleeding the brakes again while activating the ABS/DSC pumps. It stops!!

While on test drive I took the dirty girl through the car wash! It feels good to see this outside!

Last night, we popped in the M5 fuel pump. Had to swap over the 540i top to keep the barbed fitting as the M5 has a quick disconnect.

Swapped the mirror motor pins on the driver's side so pin 1 has the blue wire and pin 2 has the white wire so both door modules matched pin locations. This corrected the mirrors folding opposite ways when you hit the button.

Bled the clutch again, The feel is still not 100% but it drives.

Felt it was time to add the fresh M badge on the motor!

Counting down the days to the exhaust shop!

DrLeadFoot

Jdesign said:

Dude, you guys absolutely hammered through this. I love your evil laughter in the videos!!

I vote high flow cats and dual resonators. If that's too loud then delete the resonators and run high flow mufflers. As long as the tips go out past the rear bumper and dont turn down, it wont be as loud in the cabin.

Chubs has built some nice exhaust set ups, im sure you will figure out the best option.

Family road trip car so I want it pretty stealthy. Excited to get a gameplan in place and get this DONE!

jc43089

Leave the snow tires on all year, super stealth mode.

DrLeadFoot

Mike buttoned up the driver's side pedal area. M5 dead pedal in!!!

B C

Rising from the ashes of pitted Nikasil cylinder liners....

phenomenal!

DrLeadFoot

Did some coding to get the DSC light off and threw on the summer wheels!

Had to switch 2 sensitivity settings to S62B50 and the light went off! Went from 10 to 13 on one and 3 to 2 on the other.

I still need to get the dsc/abs module to think it is a manual but that needs to be done through the IKE (cluster) but I already popped in the M5 cluster so the VINs don't match up. Might need to pop in the 540i cluster to code it to manual then swap back to the M5 cluster. Need to look into this further.