BMW E39 525i Sport Build

Foxhole Norman

Finally decided to put one of these up, while I'm procrastinating from study :pac:

SO a few weeks ago I finally picked up the car I've wanted for a very long time, an E39 M Sport. I was lucky to find one down here in Cork and a tidy enough one at that, I did take a chance on it though as it doesn't have a service book, I think it never came over when it came to Ireland. It has a few niggly problems but every time I put the boot down =

Here's a few pictures as it is now:













To Do List:

Sort out PDC.

Remove rust on Bootlid and tiny bit on rear wing.

Smart Repair the small parking dings.

Repair cracked bumper.

Acquire Towing Eye cover.

Replace pixelated head unit with a Nav unit.

Refurb Style 66 Wheels.

New Style 37 M-Pars or Style 95's.

Sort out Cruise Control problem(Have the new Brake Switch bought that should hopefully solve it).

New Shift Knob.

Pressed Irish Plates/Sorrounds.

New Alternator Belt at next service.

Repair/Replace Driver Side rear tail light as it has condensation, not too worried about it.

New Service book/Manual :pac:

New Angel Eye Bulbs, either Halogen or LED, I'm not sure yet.

Think that just about covers what I want to get done :pac:

Already sorted out the cooling system with a new Radiator, Metal Water Pump, Thermostat and Coolant Tank Cap so that's good for another few years I hope.

Thanks for looking

Foxhole Norman

Few bits done to the car in the last few weeks, new Bonnet badge, Nightbreakers, Bosch Wipers, Irish Pressed plates and a new Ignition coil gone into Cylinder 6, hopefully sorting my Idling problem. Brake Switch and PDC to do next.

E39 M54 Ignition Coil Replacement

First thing to do when replacing the coil on the E39 is to remove the Air ducts:





This simply clicks off the airbox and a twist and pull to take it off the bulkhead.

Next, remove these two a$$holes with a 10mm socket and take off the oil filler cap to remove the cover.



You will then be met with all the ignition coils, 1-6 with one being closest the bumper, replace the oil cap while working to prevent anything foreign getting in.



Pull out the clip with a flat head screwdriver and undo the two securing bolts



Pull out the offender



Then it's simply a matter of putting in the new one and putting everything back together



Other various pictures of the car right now

New plates:



New badge:




Will be tackling the PDC and Brake Light Switch next

Foxhole Norman

Replaced the old, pixelated head unit with a new OEM looking unit, really brings the interior up in years!

Before


After


The unit is an Eonon D5124F if anyone is interested in it, seems well worth it so far and I have plans to utilize a Raspberry Pi to make an in car PC.

Foxhole Norman

Fitted the new LED lights last week:

In Day-Light:



In night/dusk light:





While the pictures show a lot of "bleed" from the rings, there's actually zero, they're very crisp, my phone's camera is not good enough to pick up on it. Very happy with them, well worth it and makes it look way better.

166man

New lights - Excellent.
New headunit - Good
New plates - Good.

M badge on Grille - GACK.

Foxhole Norman

166man wrote: »

New lights - Excellent.
New headunit - Good
New plates - Good.

M badge on Grille - GACK.

Yeah I know, I'm ashamed to say I'm getting to like it So have a few others :P

Tempted by a black grill, not sure yet though.

I've ordered an intake boot for the MAF to see if that solves the idle as the current one is hard and a bit cracked.

nerobert

the pressed german plates look batter imo

Chuck_Norris

Thanks for the pics. I've always loved the e39, and so tempted to get one next time around. Would just have to convince the wife. Subbed now. And looking forward to future pics.

Foxhole Norman

Chuck_Norris wrote: »

Thanks for the pics. I've always loved the e39, and so tempted to get one next time around. Would just have to convince the wife. Subbed now. And looking forward to future pics.

Thanks man! They're a great car, everyone that gets into mine can't get over it being 13 years old! It has as good a spec as most decent new cars, mine has PDC, Sat-Nav, Bluetooth+A2DP, DVD, TV, Dual Zone Climate, Leather, Cruise Control and most importantly, 6 cylinders

Small update today, finally replaced the faulty brake light switch, the auto seems to be shifting smoother, the Cruise activates/knocks off perfectly and there's no random braking, so far anyway. Hopefully this keeps up so all that'd need to be sorted mechanically is the rough idle which I'm hoping the new intake boot will solve.

Foxhole Norman

Not much to report other than still absolutely loving it. Very happy with the bodywork that was done except the front bumper got scuffed last week :crying: I'd say a buff will sort it out though.

Here's some recent pictures



The lower front passenger door was badly dented but here it is now:



The front bumper after it got tidied up:



Still have to get a tow hitch cover for it!

It's getting new brake pads this week as the light has just come on, already have them bought, just need to install them.


To Do List:

• Sort out PDC.
• Remove rust on Bootlid and tiny bit on rear wing.
• Smart Repair the small parking dings.
• Repair cracked bumper.
• Acquire Towing Eye cover.
• Replace pixelated head unit with a Nav unit.
• Refurb Style 66 Wheels.
• New Style 37 M-Pars or Style 95's.
• Sort out Cruise Control problem(Have the new Brake Switch bought that should hopefully solve it).
• New Shift Knob.
• Pressed Irish Plates/Sorrounds.
• New Alternator Belt at next service.
• Repair/Replace Driver Side rear tail light as it has condensation, not too worried about it.
• New Service book/Manual
• New Angel Eye Bulbs, either Halogen or LED, I'm not sure yet.

Getting there!

Dale Parish

Probably the gasket on the rear light - same happened mine - only I then found all my pins were made one with the connector :pac:
Lots of rust.

Replaced gasket and it's been OK since!

Foxhole Norman

New pads put on the rear and a new sensor, pad light not gone out yet so will have to look into that.

Foxhole Norman

Oil and Filter service last night with the brother, 4k later than when I wanted to do it but I don't think 10k was too much of a stretch.



Next job to sort is the headlights and a towing eye cover.

commited

Still love these cars. Noticed that you aren't running the climate control in auto - any reason? Is it broken? I used to leave mine at 21c on auto and then just turn the dial in between the vents if you want hotter or colder in your face!

I have bumper bars & a rear diffuser in the garage which were taken off my 530d when it was 4 years old if you're ever stuck for them!

Foxhole Norman

commited wrote: »

Still love these cars. Noticed that you aren't running the climate control in auto - any reason? Is it broken? I used to leave mine at 21c on auto and then just turn the dial in between the vents if you want hotter or colder in your face!

I have bumper bars & a rear diffuser in the garage which were taken off my 530d when it was 4 years old if you're ever stuck for them!

Only seeing this now! Thanks for the offer, much appreciated! I tend to only leave it on auto when I'm looking for heat as I find it a bit too powerful with the A/C on, I typically have the fan on only 1 or 2 bars when I have the A/C on at 16. I can be picky :pac:

New front pads fitted about 2 weeks ago now, make a massive difference to the braking and wheel cleanliness!

Steve320

Project thread is looking well dave needs a few more updates like your headlights

Foxhole Norman

To Do List:

• Sort out PDC.
• Remove rust on Bootlid and tiny bit on rear wing.
• Smart Repair the small parking dings.
• Repair cracked bumper.
• Acquire Towing Eye cover.
• Replace pixelated head unit with a Nav unit.
• Refurb Style 66 Wheels.
• New Style 37 M-Pars or Style 95's.
• Sort out Cruise Control problem(Have the new Brake Switch bought that should hopefully solve it).
• New Shift Knob.
• Pressed Irish Plates/Sorrounds.
• New Alternator Belt at next service.
• Repair/Replace Driver Side rear tail light as it has condensation, not too worried about it.
• New Service book/Manual
• New Angel Eye Bulbs, either Halogen or LED, I'm not sure yet.

Things are moving on a bit, getting a new tail cluster today and sorted my headlights out yesterday. Small bit of bodywork is needed due to an accident I had with no one to blame but myself.

Got a full 3 stage machine polish in the meantime and the transmission is getting serviced next week.

Headlights after being sorted:



Here's how she is now:

166man

Thoughts on getting steering wheel retrimmed?

S'craic with the gearbox so? Car looks really well for its polish though!

Foxhole Norman

166man wrote: »

Thoughts on getting steering wheel retrimmed?

S'craic with the gearbox so? Car looks really well for its polish though!

Steering wheel is definitely getting retrimmed along with M3 Flappy Paddles. My buddies X5 that I did yesterday had the same wheel retrimmed in Alcantara and I wasn't a fan so I'll probably go for Perforated Leather on the sides and regular leather on the top and bottom along with M stitching.

The gearbox is leaking, going in to get fresh fluid, filter and fix the leak next week, is now driving perfect again since they topped it up so I hope that's all it was.

Toyotafanboi

Your fanatical love for this car despite the BS it gives you is great to see it reminds me of me. Looks really well too, the double din unit takes decades off the interior but i've probably said that before.

How much do you reckon you are into it financially? And what would you buy if you had all that money :P?

Alanstrainor

Here's a crap photo of my steering wheel after it was done

http://imgur.com/nib5MlU

Foxhole Norman

Toyotafanboi wrote: »

Your fanatical love for this car despite the BS it gives you is great to see it reminds me of me. Looks really well too, the double din unit takes decades off the interior but i've probably said that before.

How much do you reckon you are into it financially? And what would you buy if you had all that money :P?

I think anyone that knows me on Facebook from here knows of my fanatical love for it, she's basically my SO until someone better comes along :pac:

The head unit makes all the difference, everyone that sits into it loves it!

If you exclude Tax/Insurance/Fuel/Detailing stuff I'm not into it too much:

Full set of Hankook's, €630
Head Unit, €510
Ignition Coil €50
Tail Lamp €140
Towing Eye Cover €70
Full Service €130
Transmission Service €180

Thats about it really. Now if we add in everything else for it, I'm into it well over €10k!

If I had that money would I buy anything else? No, would still get an E39, 540i if I could find one, for now, I'm very, very happy with this until I can get an M5

Alanstrainor wrote: »

Here's a crap photo of my steering wheel after it was done

http://imgur.com/nib5MlU

That's pretty much exactly what I'll be going for Alan!

commited

Foxhole Norman wrote: »

Steering wheel is definitely getting retrimmed along with M3 Flappy Paddles. My buddies X5 that I did yesterday had the same wheel retrimmed in Alcantara and I wasn't a fan so I'll probably go for Perforated Leather on the sides and regular leather on the top and bottom along with M stitching.

The gearbox is leaking, going in to get fresh fluid, filter and fix the leak next week, is now driving perfect again since they topped it up so I hope that's all it was.

I've said it on other forums, but really like what you're doing with the car. I did the M3 steering wheel with paddles upgrade on my 530i and it's worth while purely for how much better the wheel feels! The paddles are good fun but I rarely ended up using them tbh.

Foxhole Norman

commited wrote: »

I've said it on other forums, but really like what you're doing with the car. I did the M3 steering wheel with paddles upgrade on my 530i and it's worth while purely for how much better the wheel feels! The paddles are good fun but I rarely ended up using them tbh.

Sound! Most people think I'm crazy for doing what I'm doing to it, but to me, it's worth it! I'll definitely be doing it alright, while I know it'd be rare to use I'd say they can be a bit more craic on more interesting roads!

Another thing to add to the list actually is replace the underguards, they're in a bit of a state and hanging down a bit.

Toyotafanboi

Foxhole Norman wrote: »

I think anyone that knows me on Facebook from here knows of my fanatical love for it, she's basically my SO until someone better comes along :pac:

The head unit makes all the difference, everyone that sits into it loves it!

If you exclude Tax/Insurance/Fuel/Detailing stuff I'm not into it too much:

Full set of Hankook's, €630
Head Unit, €510
Ignition Coil €50
Tail Lamp €140
Towing Eye Cover €70
Full Service €130
Transmission Service €180

Thats about it really. Now if we add in everything else for it, I'm into it well over €10k!

If I had that money would I buy anything else? No, would still get an E39, 540i if I could find one, for now, I'm very, very happy with this until I can get an M5

that's actually not bad going really with a decent looking car to show for it!

tax is a sticking point though i'd say, generally speaking. personally, i do feel a little bad handing out €180 a quarter for essentially nothing when that could be the lowering springs i want or two new bridgestones etc, so the 2.5 bracket must be a bitter pill :pac:

Foxhole Norman

Toyotafanboi wrote: »

that's actually not bad going really with a decent looking car to show for it!

tax is a sticking point though i'd say, generally speaking. personally, i do feel a little bad handing out €180 a quarter for essentially nothing when that could be the lowering springs i want or two new bridgestones etc, so the 2.5 bracket must be a bitter pill :pac:

Yeah it's been pretty cheap maintenance wise, forgot to add brake pads front and rear to that list, new ceramic pads and new discs next.

€180 only got me one Hankook :pac:

I only paid it there yesterday, I said three months, yer man said Yeah grand €305 there so, the face on the fella next to me paying 200 for his full year

Foxhole Norman

Everyone likes new parts! Got it for €140 instead of the usual €180 or so that they go for.



OE Hella Tail Light to replace the old Depo leaky one. Depo:



You can see the water in this photo!



The new:



Finally have two working rear clusters again:



Also found this in the unopened first aid kit

commited

Foxhole Norman wrote: »

If I had that money would I buy anything else? No, would still get an E39, 540i if I could find one, for now, I'm very, very happy with this until I can get an M5

I wouldn't bother with a 540i - the steering set up is different, not nearly as nice as the 530i and not that much quicker - all imho of course. 530i is the pick of the non-M5 range for me, M5 is the dream for me too but doing way too many miles to justify one

Foxhole Norman

commited wrote: »

I wouldn't bother with a 540i - the steering set up is different, not nearly as nice as the 530i and not that much quicker - all imho of course. 530i is the pick of the non-M5 range for me, M5 is the dream for me too but doing way too many miles to justify one

My worry is the amount of insurance companies that'll be left that'll insure "old" cars, looking Grim to be honest!

commited

You're 100% right, have to jump to an early e39 and rock classic insurance

Foxhole Norman

Haven't been doing much with the 525 recently other than driving it! This week will be a big week for it as I have new Gloss Black Grills, new Cupholders, new Crankcase Breather System, new Thermostat and Coolant change and new Brake Pressure Sensor and Brake Fluid change. Should have all this done by mid January depending on various shipping times

Foxhole Norman

Replaced my Rocker Cover gasket today, hopefully it solves my oil leak problem!









CCV should be tackled next week!

Foxhole Norman

New MTEC Drilled and Grooved discs front and backand Mintex pads front and back arrived today, will hopefully fit them at the weekend along with the CCV system I've been putting off





New Splash Guards on the way too

Foxhole Norman

Replaced the discs and pads all around today, pads didn't need it but said I'd do them while doing the discs.

The old rotten crap:





New much improved discs:







Easy enough job bar every bolt being seized :pac:

Foxhole Norman

Replaced my CCV system in the car two weeks ago, handy enough job!

The main deconstruction:



Throttle Body ready to be removed:





The old Oil Separator:



All the old components, brittle and snapped easy when removing:



All new Genuine BMW Parts to replace them:



Cleaned the dipstick in and out while I was at it:



Job Done:



Picked up a set of 18" Style 32's from Valdelis yesterday, finally have some decent pictures of them, not to everyones taste but I love them and they transform the car, get to keep it OE too!

Foxhole Norman

Changed my oil filter housing today, €6 part, quite the bit of labour, saved myself about €200/300 doing it myself I'd say! If doing this job yourself make sure you disconnect your battery, I took both Positive and Negative connections off just in case.

Fan and shroud off first and then relieve pressure on the A/C and Aux belt and take them off, I should've replaced my aux belt here but forgot to pick one up!



Next the Power Steering reservoir bolted off the housing and swung away, room to remove the alternator now. The alternator slowed me down a bit due to the washers at the back holding it too tight to the bracket but a few gentle taps had it released. 2 Bolts holding it on, remove the connection at the back and remove the cover for the positive connection, remove this connection.

Once the Alternator is out of the way you should be able to clearly see the 6 bolts holding the housing to the block and 1 to the side of the housing. Remove these bolts and the VANOS feed line behind it. Housing should lift away.

New gasket in place:



Where the housing sits in, you can see to the right where oil was pooling and dripping down from the gasket:



Retrace your steps and it's sorted:

Mister Jingles

Why have I only seen this thread for the first time tonight ? :P

I knew ye were forever detailing it but never realised the other work. And I was up until now always under the impression that's it was a 530d :eek:

Foxhole Norman

Mister Jingles wrote: »

Why have I only seen this thread for the first time tonight ? :P

I knew ye were forever detailing it but never realised the other work. And I was up until now always under the impression that's it was a 530d :eek:

Haha sound, she's been quote the Labour of love, worth it though

Sorted a rear bootlid so she'll be going in for a front and rear end respray soon, Coilovers next, new Headlights and fog lights too, another €2.5k or so to go in the next few weeks

530d though? God no, fuel of the devil!

166man

Much like my 166 it will be some car to buy for the next owner...:D


Labour of love though eh? Know the feeling all too well...:)

Foxhole Norman

166man wrote: »

Much like my 166 it will be some car to buy for the next owner...:D


Labour of love though eh? Know the feeling all too well...:)

Next owner? If everything goes to plan there won't be a new owner :pac:

Looking forward to getting it how I want now!

Foxhole Norman

Got my car back from bodywork and damn am I completely in love again! Need to correct some small marks but nothing major!














So in love!

commited

Looks superb, only thing I'd change is the grille!

Foxhole Norman

commited wrote: »

Looks superb, only thing I'd change is the grille!

I'm a big fan of them to be honest!

Wibbs

I like your grill too TBH. Great work Sir. Your car is really coming together and the bodywork looks amazing. :eek: By any chance do you do subcontract work on non Beemers? I can provide tea/coffee/beer

Foxhole Norman

Wibbs wrote: »

I like your grill too TBH. Great work Sir. Your car is really coming together and the bodywork looks amazing. :eek: By any chance do you do subcontract work on non Beemers? I can provide tea/coffee/beer

Sound, much appreciated! I have my own small "business" doing Detail work alright, can pretty much tackle most jobs these days!

ToxicPaddy

Absolutely love the car OP. Fantastic work.

Foxhole Norman

Sound man!

Quick job this evening but made a massive difference to the car, new fogs lamps and surrounds

Old:







New:







New genuine headlights next to complete the Front end refresh

Foxhole Norman

Body now protected for a few years

Washed with G101 APC
De-Tared with Annihilate
De-Ironed with Korrosol
Clayed
Compounded with Menzerna 300 on Microfiber Discs
Polished with Menzerna 3500 on a Black Foam Finishing Pad
Entire car wiped down with GTechniq Panel Wipe
GTechniq Crystal Serum Light Ceramic Coating Applied
GTechniq EXO Hybrid Coating Applied

Not perfect by any means but I'm delighted with the results



















Headlights and trim to sort next

Installed front JOM coilovers on Saturday evening. To say I'm in love is an understatement

commited

Car looks mint dude, well done.

Can I get a bit of advice re detailing? I have a Sapphire Black BMW e92 and want to sort out the paint, it's been a bit unloved! I have a rotary polisher and meguiars #80 and Meguiars #83. The polish is probably about 8 years old - reckon it's ok? I have a clay bar, de-tar, Collinite 476 for waxing.

Any tips on pads? The #80 is a finishing glaze so I'll use it with a finishing pad, and the #83 on a cutting/polishing pad. Ideally looking to do it this weekend so all advice appreciated.

Don't hate me but it looks like the front could do with coming up a tab :pac:

Foxhole Norman

I have no experience with Megs Compounds/Polishes, especially the older versions, I used all Menzerna products on mine which worked wonders. I used their 300 Compound on a Microfiber Cutting disc and their 3500 on a black finishing pad. Rotary should cut a bit faster but be careful as you could burn the paint!

I use various pads from Chemical Guys, D&D and Flexi pads!

Foxhole Norman

Finally got around to replacing the splash guards with new genuine units, my most pointless purchase as it's so low but made a massive difference!

Before:



After:





All that was left of the old ones





Front end refresh is on the way and should be installing the rear coils soon, she won't be wanting for much soon