SCHLEPN | The E39 540itA Story

[DrLeadFoot]

M5 Diff, axles swaybar and brakes are in.  Need to order new shifter bushings (one got lost in shipping) before we get the driveshaft installed.  540i auto shifter and pedal assembly are out. 

Engine bay to-do:

- mount oil filter housing bracket to the strut tower and line up airbox mounting hole prior to drilling holes to use as a guide to where it goes.

- radiator & reservoir, hook up hoses, fan.

- install clutch line.

- bleed brakes/clutch.

- run M5 fuel lines

- install "new" servtronic solenoid & run wires to ECU.

- hook up power steering lines

- install passenger side exhaust manifolds 

GOODNIGHT!

[Jdesign]

Damn. Smashing away at this! Nice work Sir.

[DrLeadFoot]

Installed:

-Dinan short shifter, rear Turner Motorsport bushing and new OEM bushings

-M5 fuel lines and filter

-Servtronic solenoid 

Ran some trans wiring and called it a day. 

Mike is going to get after it tonight!  Probably will get the clutch line and pedal assembly in.  Hopefully driveshaft as well.

[YoungCR]

I had to look up what servtronic was, curious to hear your thoughts on how it changed the steering assist.

[B C]

This is some rapid progress

[DrLeadFoot]

YoungCR said:

I had to look up what servtronic was, curious to hear your thoughts on how it changed the steering assist. 

I'm excited to see how much it tightens the steering up.  I had a guy, Paul, in Michigan do the tuning.  Here is what he did: 

-Ews delete

-Top speed limit removal

-Rev limit and dyno rev limit increase to 7150

-Rear o2 delete

-Sap code delete but can leave the sap process on if you plan on running it. 

-Sport mode memory

-Make sport mode more linear throttle

-Sport mode steering slightly lighter at low parking lot speeds so not so stiff

-Jailbreak Tune

[SteelBlue]

Picnic or bust?

[DrLeadFoot]

SteelBlue said:

Picnic or bust?

I like that goal!

[DrLeadFoot]

Took a bit of a break but Mike dabbled a bit in between working on some other cars this weekend. 

Clutch line ran

[Jdesign]

At this rate you are going to be the fastest swap on this forum (progress wise).

[DrLeadFoot]

Had a little window from 10-12.

-Mounted up the oil filter housing & PS reservoir mounting bracket.

-Installed all heater core coolant hoses, fuel pressure regulator vacuum line, brake booster vacuum line.

-Installed driver's side intake.

-Popped in new air filters.

[DrLeadFoot]

Another little window today.  Popped in the radiator, new expansion tank, fan and a new OEM PS pressure line.  

Last night Mike got the pedal assembly in.  Just need to get the gas pedal mounted up. 

[B C]

[DrLeadFoot]

Mike chipped away a bit!  I watched the bucks game. 🤩

Gas pedal in and 1 of 2 M5 side mirrors installed! 

[DrLeadFoot]

-Driveshaft in

-Diff oil in

-Clutch lines all buttoned up

-Passenger side headers bolted up

-Crank sensor installed 

It is ready for all fluids and wiring is next!

[DrLeadFoot]

Sport button is wired up from the dash to the DME.  Hijacked some steptronic wires for this. Blue & grey and blue & yellow wires. Swapped pins and we should be good!

Fuel leak diagnostic and Brake light test switch are wired up.

Hopefully we will get the rest of the wiring done tonight! 

[B C]

That is quite the clutch hydraulic line!

[DrLeadFoot]

Got the topside wired up, sport button and servtronic!

Need to pop in new style fuel pump relay. Have run a ground wire to it and move a pin on the 540i female side of connector and the new style relay will be good to go.

Pin 2 wires behind the cluster.  One to the DME for reverse lights and the other to the clutch switch.

Changed the trans fluid. Added oil. 10w60 liqui moly.

Need to top off coolant, power steering fluid and bleed brakes/clutch.

Getting close!!

[DrLeadFoot]

B C said:

That is quite the clutch hydraulic line!

Not looking forward to bleeding that! Lol

[DrLeadFoot]

Finished up the cruise control, clutch interlock and M5 fuel pump relay wiring.  Mike added a proper ground for the fuel relay. 

Pulled the fuel relay and cranked it over a couple times to prime the oil.  Popped the relay back in and fired it up on the first try!

Bled the clutch and brakes.  Brakes felt great until we hit the gas a spun the rear wheels then the pedal went to the floor.  We think it has something to do with the DSC pump not being bled properly. 

Started buttoning up the interior and finished the cabin filters and new M5 rear wire harness covers. 

So close to being done!!

20190518_144427.mp4

Attachments:

• 20190518_144427.mp4